Crack Boundary Research Articles

Initial Studies of Tellurium Embrittlement in 316H Stainless Steel

Post-irradiation examination of the Molten Salt Reactor Experiment from the 1970s revealed intergranular cracking of the salt-facing material, Hastelloy-N, from the penetration of fission products, specifically tellurium (Te), into the components. Stainless steel 316H is a candidate salt-facing structural material for future molten salt reactors due to its excellent corrosion, oxidation, and neutron irradiation resistance. Thus, studies are needed to verify if Te may lead to material degradation of salt-facing components made from 316H. This work examined the behavior of stainless steel 316H in three conditions: as received, heat treated to 800°C for 100 h without Te, and with a highly concentrated Te environment. After exposure, mechanical testing was performed on all samples to reveal the loss of strength and ductility in the Te-exposed samples. Additional analysis of the Te-exposed 316H samples using scanning electron microscopy displayed intergranular embrittlement and energy-dispersive X-ray spectroscopy maps highlighted the infiltration of Te within grain boundary cracks. These results present the need for additional experiments to understand how Te weakens the structural material, especially in molten salt, and to eventually identify the driving mechanism for this observed behavior.

The influence of bi-directional material gradation on a mode-III crack in functionally graded material via strain gradient elasticity theory

In contrast to classical mechanics, which primarily relies on continuum assumptions and neglects micro-structural effects, the strain gradient elasticity (SGE) theory represents a paradigm shift in understanding the mechanical behavior of materials at small length scales. In this article, the influence of the bi-directional material gradation on a mode-III crack in functionally graded material via SGE theory is studied. The SGE theory uses two material characteristic lengths, ℓ and ℓ′, to account for volumetric and surface strain-gradient factors, respectively. Our investigation is centered on a material gradation model assumed to vary exponentially, with the shear modulus represented as G(x,y)=G0eβx+γy, where β and γ are material gradation constants. To address the crack boundary value problem under consideration, we employ a methodology combining Fourier transforms and an innovative hyper-singular integro-differential equation approach. Using this approach, we systematically formulate a system of equations, which can be solved by selecting suitable collocation points. The closed-form analytical expressions are derived for the standard fracture parameters such as crack surface displacement (CSD), stress intensity factor (SIF), and energy release rate (ERR). Numerical studies are illustrated for the derived standard fractures, and the influence of these parameters β, γ, ℓ, ℓ′, and applied shear load is graphically presented. Through comprehensive analysis, our aim is to provide insights into the complex interplay between material parameters, loading conditions, and crack behavior in functionally graded materials.

Effect of grain size on tensile deformation behavior of nano-polycrystalline Al and Al–Mg alloys with grain boundary segregation of Mg

Mg is easily segregated to the grain boundary of the Al–Mg alloy, which affects the mechanical properties of the alloy. In order to reveal the role of Mg element at grain boundaries in Al–Mg alloys, molecular dynamics simulation was used to study the tensile deformation behavior of nano-polycrystalline Al and Al–Mg alloys with different grain sizes. The results show that the elastic modulus and tensile strength of Al and Al–Mg alloys have a clear grain size dependence. The critical grain size at which the elastic modulus decreases as the grain size decreases is independent of Mg. As the Mg content increases to 3 at. %, the critical grain size for the transition from the Hall-Petch relationship to the inverse Hall-Petch relationship increases. The appropriate content of Mg segregation at the grain boundary can increase the elastic modulus, strength and plasticity of the alloy, and inhibit the grain boundary cracking. This result provides important theoretical support for the composition design and microstructure regulation of high-performance Al–Mg alloys.

Quantitative assessment of cracks in concrete structures using active-learning-integrated transformer and unmanned robotic platform

Quantitative assessment of cracks in concrete bridges is crucial for structural health monitoring and digital twin. However, the training of crack segmentation models relies heavily on annotation resources, and their segmentation capabilities are often unsatisfactory in terms of the accuracy of boundary location of thin cracks encountered in practice. In this paper, an active-learning-integrated crack segmentation transformer (ACS-Former) framework is proposed to maximize segmentation performance with limited annotation resources. The two-branch ACS-Former includes (1) a feature pyramid transformer (FPT) for multi-scale crack segmentation and (2) boundary difficulty-aware active learning (BDAL) to select informative images for labeling and incorporation into FPT training. Additionally, an adhesive climbing robot is proposed for image collection of hard-to-access components of large bridges. The on-site operational feasibility and practicability of the proposed ACS-Former and climbing robot are demonstrated by field experiments performed on in-service bridges, including the quantification of cracks narrower than 0.2 mm, as required by engineering codes.

Internal oxidation behavior and its effect on the surface crack formation in a Fe-Mn-Al-C high Mn steel

The correlation between internal oxidation and surface crack was investigated in high Mn steel. Time- and temperature-dependent internal oxidation behaviors are examined in the temperature ranges of 1000– 1250 °C, revealing faster and deeper oxidation along grain boundaries than in grain. Oxides at the internal oxidation layer are confirmed to be MnO and MnAl2O4. The grain boundary penetration depths of the internal oxide increase from 13 to 34 μm as the temperature increases. The tensile crack on the surface of the specimen was evaluated after 5 % straining with 10−3/s strain. Temperature-dependent crack formation probability (LAC/LT) increases also from 0.4 to 1.6 % as the temperature increases. The evolution of the internal oxidation layer during the hot compression test was investigated to clarify its role in surface crack formation. The transition of the internal oxide layer to the external oxide layer was observed. Exfoliation of the external oxidation layer was also confirmed by further compression. Driving force calculation on the internal and external oxides reveals that the abundant oxygen supply originating from the cracking of oxide and thickness reduction of the internal oxide layer transforms the internal oxide layer to scale during the compression. High-resolution analysis of the grain boundary crack reveals the cracking of grain boundary MnAl2O4. The comparison between the grain boundary oxides’ penetration depth and the crack formation behavior clarifies the grain boundary internal oxide’s crucial role in the surface crack formation in a high Mn steel. This study provides vital insights into the surface crack formation mechanism in a Fe-Mn-Al-C-based high Mn steel during hot-rolling processes, highlighting the significance of grain boundary internal oxidation in production.

Microstructure, deformation and fracture mechanism of Mg-Gd-Y-Zn-Zr alloy with different rolling routes during tension

The microstructure, deformation and fracture mechanism of unidirectional rolling (UR) and cross rolling (CR) Mg-4.7Gd-3.4Y-1.2Zn-0.5Zr alloy during tension were studied. Both rolled alloys exhibit typical bimodal microstructures, with the difference being that UR alloy has elongated grains containing rod LPSO phase, while CR alloy has relatively rounded deformed grains containing lamellar LPSO phase. After tension until fracture, the LPSO phase morphology of the two alloys remains unchanged. CR alloy exhibits a higher yield strength and lower elongation than UR alloy. Although the higher average basal <a> slip Schmid factor result in the lower yield strength of UR alloy, the activation of the high proportion of non-basal slip is responsible for its higher elongation. UR alloy and CR alloy exhibit ductile fracture and quasi cleavage fracture characteristics, respectively. For UR alloy, a variety of dislocations accumulated near grain boundary and the weak slip transfer effects between grains both contributes to the propagation of grain boundary cracks. However, the effects of weak interfacial bonding between metastable lamellar LPSO phase and matrix, along with the similar orientation and higher geometric compatibility of CR alloy, lead to the rapid spread of transgranular cracks.

Sodium-Alginate-Doped Lignin Nanoparticles for PBAT Composite Films to Dually Enhance Tensile Strength and Elongation Performance with Functionality.

It is a formidable challenge in thermoplastic/lignin composites to simultaneously boost tensile strength and elongation performance due to the rigidity of lignin. To address this issue, sodium-alginate-doped lignin nanoparticles (SLNPs) were prepared by combining solvent exchange and a coprecipitation method and used as an eco-friendly filler for poly(butylene adipate-co-terephthalate) (PBAT). The results indicated that the 1% polyanionic sodium alginate solution contributed to the formation of SLNP in lignin/THF solution. SLNP with a mean hydrodynamic diameter of ~500 nm and a Zeta potential value of -19.2 mV was obtained, indicating more hydrophobic lignin nanoparticles and a smaller number of agglomerates in SLNP suspension. Only 0.5 wt% SLNP addition improved the yield strength, tensile strength, and elongation at break by 32.4%, 31.8%, and 35.1% of the PBAT/SLNP composite films, respectively. The reinforcing effect resulted from the rigid aromatic structure of SLNP, whereas the enhanced elongation was attributed to the nanostructural feature of SLNP, which may promote boundary cracking. Additionally, the PBAT/SLNP composite films displayed excellent ultraviolet (UV) resistance with a UV shielding percentage near 100% for UVB and more than 75% for UVA, respectively. The addition of SLNP hindered water vapor, enhancing the moisture barrier properties. Overall, this study provides an effective strategy to eliminate the decrement in elongation performance for PBAT/lignin composites and suggest they are good candidates to be extensively utilized.

Hierarchical Supramolecular Aggregation of Molecular Nanoparticles for Granular Materials with Ultra High-Speed Impact-Resistance.

The high-speed impact-resistanct materials are of great significance while their development is hindered by the intrinsic tradeoff between mechanical strength and energy dissipation capability. Herein, the new chemical system of molecular granular material (MGM) is developed for the design of impact-resistant materials from the supramolecular complexation of sub-nm molecular clusters (MCs) and hyper-branched polyelectrolytes. Their hierarchical aggregation provides the origin of the decoupling of mechanical strengths and structural relaxation dynamics. The MCs' intrinsic fast dynamics afford excellent high-speed impact-resistance, up to 5600 s-1 impact in a typical split-Hopkinson pressure bar test while only tiny boundary cracks can be observed even under 7200 s-1 impact. The high loadings of MCs and their hierarchical aggregates provide high-density sacrificial bonding for the effective dissipation of the impact energy, enabling the protection of fragile devices from the direct impact of over 200 ms-1 bullet. Moreover, the MGMs can be conveniently processed into protective coatings or films with promising recyclability due to the supramolecular interaction feature. The research not only reveals the unique relaxation dynamics and mechanical properties of MGMs in comparison with polymers and colloids, but also develops new chemical systems for the fabrication of high-speed impact-resistant materials.

Oxidation mechanism and microstructure evolution of invar alloy with high temperature annealing process

The high temperature oxidation behavior of Fe–36Ni Invar alloy in the forged billet stage and hot rolled rod stage in the compressed air atmosphere has been systematically studied. The results show that the oxide layer can be divided into the external oxide layer composed of Fe2O3, Fe3O4 and NiO, and the inner transition oxide layer composed of FeO, Fe2O3, Fe3O4 and NiO. In addition, hot rolled rod samples treated by solution and rolling have higher oxidation resistance. The mechanism of O diffusion during oxidation is analyzed, and it is found that the O atom adsorbed on the surface of the substrate diffuses into the grain along the grain boundary. The grain boundary is the optimal path for O diffusion to the interior of the material, which results in the degree of intergranular oxidation of the alloy being greater than the degree of intragranular oxidation. In summary, the oxidation resistance of Invar alloy can be improved by proper solution treatment and avoiding the formation of grain boundary cracks during production.

Crack growth and fracture mechanics of CuCrFeNiCo high-entropy alloy during tension testing

In this work, the crack growth and fracture mechanics of CuCrFeNiCo high-entropy alloy (HEA) during tension process are studied through molecular dynamics simulation method. The single-crystalline, nanocrystalline, and twinned-nanocrystalline CuCrFeNiCo HEA samples with an initial crack are prepared. The influences of boundary conditions, crack length and crystallographic orientation are considered in detail. The results indicate that the phase transition from face-centered cubic (FCC) structure into hexagonal close-packed (HCP) structure and the appearance of Shockley dislocations are the majority in all samples. The dislocations appear most densely in the twinned-nanocrstalline sample and most sparsely in the single-crystalline sample. The growth of the initial crack combined with the formation and expansion of new cracks along the grain boundaries (GBs) is the determining factor in the fracture mechanics of the CuCrFeNiCo HEA samples. The deformation capacity of the samples with free boundary conditions along the y-axis is better and the plastic deformation process is longer than the samples with periodic boundary conditions along the y-axis. The tensile strength values of the CuCrFeNiCo HEA samples change significantly in the range from 2.61 GPa to 7.75 GPa when changing the simulation conditions. The von Mises stress in the grains is markedly lower than that in the GBs.

Increased long-term stress-rupture life of a nickel-based superalloy with relatively homogeneous duplex grain size distributions

Effect of duplex grain size distributions on long-term stress-rupture life of Nimonic 80A had been investigated. Non-homogeneous duplex grain size distributions greatly reduce stress-rupture life. Regional distribution of coarse grains is not good for acquiring high stress-rupture life, the formation of micro-void and propagation of cracking can easily occur at coarse grain boundary especially when plate-like Cr23C6 precipitates at grain boundary. But relatively homogeneous duplex grain size distributions are of great significance in improving stress-rupture life, the samples even possess the life value up to more than 13000 h especially when hardly any plate-like Cr23C6 precipitates at grain boundaries. Slightly increased Ti/Al ratio from 1.65 to 1.80 is also beneficial to obtain a significantly longer stress-rupture life value. The γ′ phase is very stable and always exhibits a coherent orientation relationship with γ on {100} and {111} atomic planes. The grain boundary cracking will not easily appear at the early stage of stress-rupture test in the samples with relatively homogeneous grain size distribution, the coarse and adjacent fine grains possess better deformation adjustability, and the grain boundary cracking is apparently wider and the number of cracking is also getting more after fracture for the sample with longer stress-rupture life.

Identification of historical maximum load on concrete beams based on crack and deformation response using knowledge-embedded machine learning algorithms

This study introduces an innovative method for identifying the historical maximum load on concrete beams, utilizing a multi-layer back propagation (BP) neural network model with physically interpretable features as inputs. The method establishes a mapping relationship among four-dimensional features (boundary constraints, system parameters, cracks, and deformations) and the maximum load in the load history, using incremental load action and structural response. Moreover, a hybrid optimization algorithm, combining Hunter Prey Optimization (HPO) and Particle Swarm Optimization (PSO), is introduced to optimize the model's parameters. The method is compared with commonly used machine learning models, demonstrating its accuracy and reliability. Additionally, the study performs a sensitivity analysis of the input features using the proposed intelligent identification model. The results reveal that the proposed intelligent identification model exhibits small prediction errors on both the training and testing sets, with average absolute percentage errors of 16.46 % and 19.56 %, and determination coefficients of 0.922 and 0.8185, respectively, showcasing its strong robustness and generalization capability. Compared to the non-optimized multi-layer BP neural network model, the proposed model achieves a reduction in average absolute percentage errors of 39.59 % and 48.33 % on the training and testing sets, respectively.

Length Scale Insensitive Phase-Field Fracture Methodology for Brittle and Ductile Materials

We present length scale insensitive phase-field fracture models for brittle and ductile fracture to address the deficiencies of widely implemented models which over-estimate crack dissipation. An approach is proposed to attain a regularization length scale insensitive mechanical response, which considers a continuous approximation of a crack boundary with a function of infinite support. This is in contrast to previous approaches to attain a length scale insensitive response which exploited approximations of the crack boundary with functions of finite support. The choice of these functions with finite support creates implementational challenges which are avoided in the presented quasi-brittle and ductile fracture models with infinite support of the phase-field. The capability of these models is demonstrated in several benchmarks with attention given to the sensitivity of the structural response with respect to the choice of regularization length scale. The models are validated against a three-point bending test on a concrete specimen and an in-plane shear test on a steel specimen.

Crystallographic micro-mechanism of faceted crack initiation in near-α titanium alloy Ti6321 under room-temperature fatigue and dwell fatigue loadings

Crack initiation mechanism of dwell fatigue has always been a key problem in rationalizing the dwell effect, and it is not completely understood yet. This study conducted stress-controlled low-cycle fatigue and dwell fatigue tests on Ti-6Al-3Nb-2Zr-1Mo alloy with bimodal microstructure to reveal its microstructural characteristics and crack initiation mechanisms. The study demonstrated that the faceted primary α nodules located near the specimen surface acted as crack initiation sites during both fatigue and dwell fatigue tests. Slip trace analysis revealed that faceted cracking occurred at (0001) basal plane with the maximum Schmid factor value through a special cracking mode referred to as (0001) twist boundary cracking. Innovative criteria of parameters C1 and C2 were proposed based on experimental observation and molecular dynamics simulations, which well identify candidates for (0001) twist boundary crack nucleation. It demonstrated that grain pairs combining a moderately high Schmid factor for basal slip and a well-orientated Burgers vector in the out-of-surface plane was the preferable location for surface (0001) twist-boundary crack initiation, and grain pairs combining a high Schmid factor for basal slip and a high normal stress on basal plane are perfect candidates for subsurface cracking. Based on this, phenomenological models are proposed to explain the surface (0001) twist-boundary cracking mechanism from the perspective of surface extrusion-intrusion-induced micro-notches.

The Role of Extrusions and Intrusions in the Initiation and Intergranular Growth of Fatigue Cracks

The role of extrusions and intrusions in the initiation and growth of intergranular fatigue cracks is studied by performing strain‐controlled fatigue experiments on polycrystalline copper and by analyzing the development of intergranular crack initiation and resulting fracture surfaces. Fatigue cracks initiate either in the persistent slipbands within a grain or on the grain boundaries. The grain boundary initiation mechanism is due to the production of extrusions and intrusions on the grain boundaries that decrease the grain boundary cohesion forming submicroscopic crack nuclei. The alternating extrusions and intrusions are found also on the grain boundary facets of the fracture surface of a growing fatigue crack. Up to three slip systems are identified on the facets of cracked grain boundaries. Their form and height are found using scanning electron microscope observations and focused ion beam sectioning. A mechanism similar to intergranular grain boundary crack initiation is considered to explain the formation of grain boundary facets. A novel mechanism of intergranular fatigue crack growth is proposed based on the damaging effect of the extrusions and intrusions produced in the cyclic plastic zone of the growing fatigue crack.

Equivalent characterization of initial crack size of blunt notched components based on test data and physical model

The precise definition of initial crack size applicable to fracture mechanics is crucial for predicting the total fatigue life of structural components. Given that the demarcation between crack formation and crack propagation depends not only on the material but also on the stress level, theoretical and experimental procedures for defining the crack boundary point are developed. Underlying the procedure is that the designed notched members have the same local stress distribution as the structure. Consequently, the fatigue life and initial crack size of S355J2 steel notched components with different scales but similar stress fields were predicted and compared with experimental data. Results show that fatigue life predictions fall within ±2 factor band, and the crack initiation size obtained by AM is closest to the experimental results, with a difference of less than 30.2%, which proves that the approach of treating the initial crack size as a function related to fatigue life and fatigue notch factor is reasonable.

Understanding the influence of environmental conditions on the low cycle fatigue behaviour of high strength low alloy (HSLA) steel under air and corrosive (3.5% NaCl) conditions

Offshore structures which are made up of high-strength low alloy (HSLA) steel experience fatigue load due to sea waves and corrosion. In the present work, the influence of environmental conditions (air and 3.5 % NaCl solution) on the strain-controlled fatigue life of High Strength Low Alloy (HSLA) steel has been determined. Low cycle fatigue experiments were conducted on HSLA steel specimens of 12 mm diameter which were prepared parallel to the rolling direction. The strain amplitude was varied in the range of 0.4 to 0.7 % for a constant test frequency of 0.3 Hz. For all the total strain amplitudes (Δεt/2), a significant reduction in fatigue life was observed while testing the specimens under the presence of 3.5 % NaCl solution compared to the air environment. Microscopic investigation indicates that rigorous grain boundary oxidation has happened, and it has created the grain boundary cracking and several sites for fatigue crack initiation and propagation. The presence of corrosive compounds (Fe2O3, FeOOH) was also confirmed by the X-ray diffraction patterns. In addition, mixed modes (transannular and intergranular) of fractures were observed due to the presence of 3.5 % NaCl solution.

Thermal cycling behavior of Yb3+-Ce4+ co-doped La2Zr2O7-based TBCs: Experimental and theoretical research

The thermal cycling behavior of Yb3+-Ce4+-La2Zr2O7/YSZ (LYZCO/YSZ) TBCs was systematically investigated via experiment and first-principles calculation. Results suggest that ceramic grain boundary cracking is the root cause of LYZCO/YSZ TBCs thermal cycle failure. Compared to La2Zr2O7/YSZ TBCs, LYZCO/YSZ TBCs own an outstanding thermal cycle life at 1100 ℃, which is attributed to LYZCO's higher TEC (10.431×10−6/K, 1100 ℃) and lower thermal conductivity (1.299 W/(m·K), 1100 ℃). Furthermore, Griffith's separation work of the LYZCO/YSZ interface is merely −0.576 J/m2, implying that the LYZCO/YSZ TBCs are particularly prone to cracking at this interface. Weakly bonded La-O is the first site at this interface cracking.

Role of multi-variant deformation-induced HCP plates in cryogenic mechanical properties of an FCC high entropy alloy

We investigated the temperature-dependent mechanical properties and deformation mechanisms of the Fe49.5Mn30Co10Cr10C0.2Ti0.1V0.1Mo0.1 alloy from room temperature to cryogenic temperatures. As the deformation temperature decreased, both the strength and strain-hardening rate increased, while ductility tended to decrease. The higher strength of the material deformed at 123 K, compared to that deformed at 223 K, can be attributed to the larger number of multivariant HCP plates and higher hetero deformation induced (HDI) strengthening in the former. Multivariant deformation-induced HCP plates were the primary deformation mechanisms at all deformation temperatures, and cryogenic deformation activated intersecting shear, defined as the primary HCP plate being sheared by the secondary HCP plate. This mechanism contributed to stress relaxation and enhanced deformation accommodation. The reduced ductility observed in the material deformed at 123 K may be attributed to coarse edge and grain boundary cracks, which were more pronounced when the TRIP effect was enhanced.

Nonlinear motion characteristics of the high-temperature superconducting levitation system with boundary crack

High-temperature superconducting levitation systems have nonlinear behaviors, such as the period-doubling bifurcation and chaotic vibration under external excitation, in connection with the nonlinear hysteresis interaction between the high-temperature superconductors (HTSC) and permanent magnet. The HTSC is a non-ideal type II superconductor in which the fracture is generated internally during manufacturing, and the material properties are brittle. The HTSC tends to crack under a strong magnetic field and electromagnetic force, and its internal defects are likely to cause structural damage with the variable Lorentz force. The fracture performance of the superconducting magnetic levitation system will affect the temperature variation of HTSC, in which the temperature is coupled with the internal electromagnetic force. In this paper, we analyze the fracture characteristics of the HTSC in nonlinear vibration with thermal effect. A superconducting magnetic levitation system model with boundary cracks is applied to study the coupling of multiple physical fields in dynamic processes. The Maxwell equation and superconducting electromagnetic constitutive equation are used to obtain the superconductor’s current density, and the temperature is calculated through the heat conduction equation. The superconducting magnetic flux flow and creep model is applied to analyze the magnetic flux motion inside the superconductors. We compare the superconducting levitation system’s electromagnetic force, temperature, and current density with four critical current densities. The numerical results show that the critical current density of superconductors significantly impacts bifurcation motion, and the temperature of the crack tip of the superconductors varies greatly during vibration, causing the superconductor to lose its superconductivity.