We investigate the size scaling of the macroscopic fracture strength of heterogeneous materials when microscopic disorder is controlled by fat-tailed distributions. We consider a fiber bundle model where the strength of single fibers is described by a power law distribution over a finite range. Tuning the amount of disorder by varying the power law exponent and the upper cutoff of fibers' strength, in the limit of equal load sharing an astonishing size effect is revealed: For small system sizes the bundle strength increases with the number of fibers and the usual decreasing size effect of heterogeneous materials is only restored beyond a characteristic size. We show analytically that the extreme order statistics of fibers' strength is responsible for this peculiar behavior. Analyzing the results of computer simulations we deduce a scaling form which describes the dependence of the macroscopic strength of fiber bundles on the parameters of microscopic disorder over the entire range of system sizes.

Forecasting the imminent catastrophic failure has a high importance for a large variety of systems from the collapse of engineering constructions, through the emergence of landslides and earthquakes, to volcanic eruptions. Failure forecast methods predict the lifetime of the system based on the time-to-failure power law of observables describing the final acceleration towards failure. We show that the statistics of records of the event series of breaking bursts, accompanying the failure process, provides a powerful tool to detect the onset of acceleration, as an early warning of the impending catastrophe. We focus on the fracture of heterogeneous materials using a fiber bundle model, which exhibits transitions between perfectly brittle, quasi-brittle, and ductile behaviors as the amount of disorder is increased. Analyzing the lifetime of record size bursts, we demonstrate that the acceleration starts at a characteristic record rank, below which record breaking slows down due to the dominance of disorder in fracturing, while above it stress redistribution gives rise to an enhanced triggering of bursts and acceleration of the dynamics. The emergence of this signal depends on the degree of disorder making both highly brittle fracture of low disorder materials, and ductile fracture of strongly disordered ones, unpredictable.

We investigate the effect of the amount of disorder on the statistics of breaking bursts during the quasi-static fracture of heterogeneous materials. We consider a fiber bundle model where the strength of single fibers is sampled from a power law distribution over a finite range, so that the amount of materials' disorder can be controlled by varying the power law exponent and the upper cutoff of fibers' strength. Analytical calculations and computer simulations, performed in the limit of equal load sharing, revealed that depending on the disorder parameters the mechanical response of the bundle is either perfectly brittle where the first fiber breaking triggers a catastrophic avalanche, or it is quasi-brittle where macroscopic failure is preceded by a sequence of bursts. In the quasibrittle phase, the statistics of avalanche sizes is found to show a high degree of complexity. In particular, we demonstrate that the functional form of the size distribution of bursts depends on the system size: for large upper cutoffs of fibers' strength, in small systems the sequence of bursts has a high degree of stationarity characterized by a power law size distribution with a universal exponent. However, for sufficiently large bundles the breaking process accelerates towards the critical point of failure which gives rise to a crossover between two power laws. The transition between the two regimes occurs at a characteristic system size which depends on the disorder parameters.