Crack Density Research Articles

A novel deep learning‐based technique for efficient characterization of engineered cementitious composites cracks for durability assessment

AbstractEngineered Cementitious Composites also known as Strain‐hardening cementitious composites (SHCCs) has unique cracking patterns like cracks that have tiny widths and showcase high density. All of this makes it difficult and laborious to compute crack parameters from crack patterns. Unfortunately, this is an essential part of assessing durability and micromechanical modeling. SHSnet is developed to perform end‐to‐end semantic segmentation of SHCC cracks. SHSnet is efficient, attention based deep encoder‐decoder network with large receptive field. Loss function based on Tversky function were used for training the model. SHSnet with loss function shows promising result with mPrecision, mF1Score and mIoU of 0.87, 0.84 and 0.83 respectively for complex SHCC cracks while requiring at least an order of fewer computational parameters than those in the literature. An image processing unit is then used to estimate the width, number, and length of the cracks from the segmentation mask. Test results show that the computed crack parameters with SHSnet are exactly the same as that computed with an optical microscope but require ~100× less time. Results demonstrate that SHSnet works equally well in SHCCs with different surface textures, crack density, and widths; the final result was far superior to a conventional technique. This technique also shows promising results in an automatic evaluation of crack parameters relevant to durability and visualizing crack patterns even in the presence of artifacts during progressive testing. The results also demonstrate the necessity to accurately and densely calculate crack length and maximum crack width; else the durability results are expected to be significantly more conservative than the actual value.

Fluid upwelling across the Hikurangi subduction thrust during deep slow-slip earthquakes

AbstractSlow-slip events at global subduction zones relieve tectonic stress over days to years. Through slow-slip cycles, high fluid pressures observed at the top of subducting plates are thought to fluctuate, potentially due to the valving action of an impermeable layer near the plate interface. We model teleseismic scattering data at the Manawatu deep slow-slip patch at the Hikurangi margin in New Zealand and find high seismic P-to-S wave velocity ratios, VP/VS, in the upper ~5 km of the subducting Pacific Plate, reflecting sustained elevated fluid pressures that decrease during slow-slip and increase during inter-slow-slip periods. Within a ~ 3 km thick lower crustal layer of the overriding Australian Plate, decreasing VP/VS during inter-slow-slip periods reflects permeability reduction due to mineral precipitation. Increasing VP/VS during slow-slip reflects increasing permeability and crack density, facilitating upward fluid transfer through this layer. Our results suggest it acts as a valve to relieve high fluid pressures in the subducting slab.

Numerical Model for Investigating Effects of Cracks and Perforation on Polymer Electrolyte Fuel Cell Performance

The presence of cracks in the microporous layer (MPL) of polymer electrolyte fuel cells (PEFCs), often occurring during the membrane electrode assembly manufacturing process, has a significant impact on cell performance. However, the exact influence of crack presence, density, and patterns within MPLs on cell performance and transport behaviors remains unclear. This study introduces a three-dimensional macroscale model of PEFCs aimed at investigating the effects of MPL cracks and gas diffusion layer (GDL) perforations on cell performance and transport behavior. This model offers several advantages, including the ability to potentially integrate the effects of flow channel design in future. Additionally, the model can seamlessly incorporate electrochemical reactions and explore phenomena within the catalyst layers (CLs), expanding simulation capabilities beyond water transport alone. The findings suggest that MPL cracks contribute positively to performance by facilitating water drainage. Furthermore, when combined with perforations in GDLs, MPL cracks can significantly enhance performance by providing pathways for water transport. Overall, this study provides valuable insights into developing models for optimizing PEFC performance and underscores the need for further research and development in this area.

Microstructure and mechanical performance of cold spray Cr coatings

Cold spray deposition has emerged as a promising method for applying protective coatings in the nuclear industry, particularly for enhancing the accident tolerance of fuel assemblies. In this process, helium gas is often used to propel solid powder particles towards the target substrate, however, nitrogen gas is also considered due to its significantly lower cost. In this study, we investigate the influence of nitrogen and helium gas as propellants on the properties and microstructure of pure chromium (Cr) coatings on zirconium (Zr) alloy cladding tubes. Employing Scanning Electron Microscopy (SEM) and electron and x-ray diffraction techniques (EBSD, XRD), we explore the structural characteristics of the coatings. Additionally, in-situ SEM tensile testing at room temperature, coupled with Digital Image Correlation (DIC), is utilized to assess the coating cracking behaviour. Our findings reveal distinct differences in coating morphology and residual stress between nitrogen and helium propelled Cr coatings. The nitrogen-propelled coating exhibits a more porous structure with smoother coating/substrate interfaces and lower compressive residual stress compared to the helium-propelled one. This results in earlier strain-induced crack initiation and higher crack density at lower strains (0.5–2%). However, at higher strains (2–5%), both coatings demonstrate identical crack saturation densities (saturated number of cracks per unit length), accompanied by similar crack toughening mechanisms and evidence of shear strain bands at intercrack regions, indicative of plasticity onset.

Electro-discharge machining using copper-coated additively-manufactured AlSi10Mg electrodes

Customized fabrication of electrodes for electro-discharge machining (EDM) is considered as a useful emerging application of metal additive manufacturing technologies for building complex shaped tools in a short period of time. This approach of producing electrodes not only effectively addresses the design flexibility and complexity issues of the tools but also enables the use of various materials so as to ingrain the desired properties in them. The current study explores the production of laser powder bed fusion (LPBF) AlSi10Mg tools for machining of titanium alloy. Moreover, it explicitly assesses the machining performance of additively manufactured electrodes when the tools are subjected to a thin layer of copper coating. Three types of acidic baths are used for electroless coating of tools. The machining performance of the tools in terms of material removal rate, tool wear rate, surface crack density, surface roughness, white layer thickness, and microhardness of the white layer is compared for different electroless copper coating processes. It is observed that the coated tools significantly enhance material removal rate; however, uncoated LPBF tools exhibit superior surface morphology and surface roughness.

Evaluation of fatigue damage of structural steel based on attenuation of laser-induced surface acoustic wave

ABSTRACT In this paper, the fatigue damage degree of low-alloy structural steel is evaluated by using the attenuation characteristics of laser-induced surface acoustic wave (SAW) during propagation. Taking the typical structural steel material Q345 as an example, a cracks model of fatigue damage is established, and the finite element method is used to solve the model. The results showed that the attenuation coefficient of SAW can reflect the depth and density of fatigue cracks. The surface measurement experiments of specimens with stress cycles of 0, 50000, 100000, 150000, and 200,000 showed that with the increase of stress cycles, the attenuation coefficient of SAW increases as a whole, indicating that it is feasible to evaluate the fatigue damage degree based on the attenuation of SAW. A method of applying tensile stress to the material to improve the sensitivity of fatigue damage evaluation is proposed. The tensile stress is used to offset the horizontal amplitude of the SAW, keeping the fatigue cracks in an open state and increasing the attenuation coefficient of SAW. The attenuation coefficient measurement experiment shows that this method is feasible.

Analysis of initiation and growth of new transverse cracks in high crack density regions in cross-ply laminates

In cross-ply laminates under loading, multiple intralaminar (transverse) cracking in the 90-layers causes laminate stiffness reduction which can be predicted by analytical models studying average of the stress perturbation between transverse cracks. The commonly used analytical models such as shear-lag type or variational-type models assume that stress in damaged 90-layers does not depend on the laminate thickness coordinate. But with increase in crack density, the stress perturbations created by transverse cracks start to interact, generating high stress gradients in through-the-thickness direction in the 90-layers. Location of a new crack and features of its propagation in a high stress gradient region between two cracks in a cross-ply laminate are analyzed in this paper. FEM is used to calculate stress distribution between two cracks. The location of the next crack and its initial orientation is found using principal stresses and orientation of principal axes. Most often these cracks are initiated at ply interface in the middle between already existing cracks. Their propagation across the layer thickness is analyzed using energy release rate based criterion. It is shown that at very high crack density the crack propagation across the layer thickness is unstable in the beginning, but it is stopped when approaching the middle of the layer where the crack opening becomes zero. Presence of local delaminations at the tips of existing cracks changes the energy release rate for propagation of new transverse cracks.

Role of Ti-6Al-4V addition in modulating crack sensitivity, solidification microstructure and mechanical properties of laser powder bed fused γ-TiAl alloys

Solidification cracking is still the primary challenge for laser powder bed fusion (LPBF) without high-temperature preheating of γ-TiAl alloys. Circumventing the peritectic reaction and promoting β-solidification by adding the β-stablizing elements have been proved to be an effective way to suppressing the crack formation. In this work, we attempted a more economic method to realize β-solidification via the addition of Ti-6Al-4V (TC4) pre-alloyed powder. The results showed that the TC4 addition successfully changed the solidification path from L→L+β→L+α→α→α+γ→α2+γ to L→L+β→β→α+β→α2+β/B2. As a result, the solidified microstructure was mainly comprised of primary α2 phase and small amount of retained β/B2 (8.5 %) phase distributed along the molten pool boundary. What's more important was that the TC4 addition led to a 44.6 % decrease in crack density. Contributions to low hot cracking sensitivity were found to mainly origin from the relatively lower cooling rate, higher fraction of low-angle grain boundaries (LAGBs) and smaller dendrite coalescence undercooling induced by the TC4 addition. Besides, the smaller temperature interval (10.63K) in the final solidification stage (0.90<fs < 0.94) for the TC4/TiAl alloy was also conducive to facilitate the liquid feeding and dendrite coalescence.

Characteristics of coal crack development and gas desorption in the stress affected zone of rock pillar

Coal (Rock) pillar retaining in the mining of protective layer would cause gas dynamic disaster in the protected layer. Based on the gas geological conditions of the two-layer coal seam in Jinhe Coal Mine of Yaojie Mining District, the stress evolution law of coal seam in the rock pillar affected area was studied by theoretical analysis and numerical simulation, and the crack development law of coal seam in different loading stages under conventional triaxial loading was studied by CT scanning technology. With the analysis of the stress evolution and crack development of coal in rock pillar affected area, the gas extraction effect under different stress states and the gas desorption law after pressure relief antireflection were studied on site. The results showed that the stress of coal in the rock pillar affected area is in the approximate elastic stage of the conventional triaxial stress-strain curve, and the cracks of coal are mainly closed at this stage. Meanwhile, the increase of stress leaded to the decrease of coal permeability and the poor gas extraction effect. CT scanning tests under conventional triaxial loading were carried out in the laboratory, and three-dimensional visual models of coal sample cracks were constructed at different loading stages. When loading to the linear elastic stage, the crack volume and surface area were reduced by 74% and 71% compared with the ones in initial state. At the same time, the expression between stress σ and crack density T was further established. After comprehensive control measures such as intensive drilling discharge, presplitting blasting and coal water injection were taken to the coal in rock pillar affected area, the crack density T could reach the crack development level of the conventional triaxial loading softening stage, realizing the crack development of the coal under low stress. The enclosed gas in front of the coal could desorption flow during the roadway driving. And the predict index value K1 also decreased from 0.57 mL/(g·min1/2) to 0.17 mL/(g·min1/2) continuously. The safety of coal roadway in rock pillar affected area was realized, and the accuracy of numerical simulation and laboratory test results was verified, which had certain reference significance for coal roadway excavation under this similar conditions.

Machining performance analysis of wire-EDM for machining of titanium alloy using multi-objective optimization and machine learning approach

This study investigates the multi-objective optimization of process parameters in wire electrical discharge machining (WEDM) using titanium alloy grade 5 and zinc-coated brass microwire. The novelty lies in the comprehensive investigation of the effects of varying pulse on time (Ton), wire tension (WT), and wire feed rate (WF) on output responses, including surface roughness (SR), surface crack density (SCD), corner diameter (CD), and kerf width (KW). The Box-Behnken design, a sophisticated response surface methodology (RSM) technique, is employed to efficiently explore the complex relationships and interdependencies between these input and output parameters. The study's novel approach incorporates machine learning algorithms, including decision tree, light gradient boosting machine (LightGBM) and random forest, to predict the characteristics of the laser-cut components based on the input parameters. The contour plots generated provide valuable insights into the underlying patterns and associations between input and output features, aiding in the understanding of the WEDM process. The results reveal that the optimized values for SR, SCD, CD, and KW are obtained at specific machining conditions: Ton of 10 μs, WF of 3.79 m/min, and WT of 8 gf. Among the machine learning algorithms employed, random forest outperforms the others in predicting KW, SR, SCD and CD, exhibiting significantly lower mean squared error (MSE) and mean absolute error (MAE) values. This study contributes to the field of WEDM by providing a comprehensive analysis, incorporating advanced experimental design techniques and machine learning algorithms, which can aid in process optimization and quality control in manufacturing applications.

Crack analysis in laser powder bed fusion-fabricated 2195 Al-Li alloy: An in-depth examination of influential variables

Laser powder bed fusion (LPBF) of high-strength 2195 Al-Li alloys offers significant industrial potential, yet the process is hindered by a high susceptibility to hot cracking. This study systematically investigates the hot cracking mechanisms and the key processing parameters influencing crack formation in LPBF-fabricated 2195 Al-Li alloys. Extensive experimental analysis revealed that crack density is significantly affected by scanning velocity and laser power, with scanning velocity identified as the most critical factor through a neural network model and a crack susceptibility model. The study demonstrates that achieving crack-free samples requires extremely low scanning velocities, as higher velocities exacerbate crack formation, particularly at high-angle grain boundaries (HAGBs). The findings also highlight the limitations of preheating in reducing crack susceptibility, emphasizing the importance of precise control over processing parameters to mitigate cracking in LPBF-fabricated 2195 Al-Li alloys.

Prediction of shale bedding-parallel crack density based on the SH-SH wave inversion of the VTI media

Bedding-parallel cracks relate to hydrocarbon accumulation and can be beneficial for hydraulic fracturing. The prediction of bedding-parallel crack density (BCD) from seismic data is difficult because the development of bedding-parallel cracks has limited effects on the velocities and density of subsurface formation. Well logs of the Qingshankou (K2qn) shales in the Songliao Basin, northeast China, reveal that the target formations represent extremely strong seismic anisotropy (&gt; 40%), and the magnitude of S-wave anisotropy highly relates to the density of bedding-parallel cracks (up to 2500 m−1). We present a novel BCD prediction method using the reflected seismic shear wave. The S-wave anisotropy parameter γ is first inverted from the SH-SH wave by using a stepwise inversion method based on a new shear wave reflection coefficient approximation. Furthermore, the highly correlated rock-physics relationship between BCD and the anisotropy parameter γ facilitates accurate BCD estimation. Field data application on a real seismic shear wave data set acquired from the study area demonstrates the viability of the proposed method. The investigation provides a useful tool for the characterization of ‘sweet-spots’ of shale-oil reservoir formation.

Revealing the oxidation growth mechanism and crack evolution law of Si-HfO2/Yb2Si2O7/Yb2SiO5/high-entropy hafnate thermal/environmental barrier coatings during thermal cycling

The Si-HfO2/Yb2Si2O7/Yb2SiO5/(Dy0.2Ho0.2Er0.2Tm0.2Lu0.2)2Hf2O7 thermal/environmental barrier coating (T/EBC) protects ceramic matrix composites (CMCs) from turbine multi-corrosive media erosion. Challenges persist in the thermal cycling performance of multi-layered T/EBC, notably in understanding the oxidation of the Si-HfO2 bond coat, compatibility of its mixed thermally grown oxide (m-TGO) with adjacent layers, and the evolution of cracks caused by thermal cycling. Utilizing plasma spraying physical vapor deposition (PS-PVD), this T/EBC on CMC substrates withstands up to 200 hours at 1450 ℃ to 1550 ℃. The m-TGO oxidation follows a parabolic growth curve, with oxygen diffusion activation energies of 160.31 kJ/mol from 1450 ℃ to 1500 ℃, and 125.16 kJ/mol from 1500 ℃ to 1550 ℃. Thermo-mechanical calculations indicate that elastic strain energy accumulation causes interlaminar cracks between m-TGO and adjacent layers. Controlling mud crack density is key to preventing the stress attraction at the tips of bifurcated cracks, thereby avoiding the formation of interlaminar cracks.

Structural and excitonic properties of the polycrystalline FAPbI3 thin films, and their photovoltaic responses

Faormamadinium based perovskites have been proposed to replace the methylammonium lead tri-iodide (MAPbI3) perovskite as the light absorbing layer of photovoltaic cells owing to their photo-active and chemically stable properties. However, the crystal phase transition from the photo-activeα-FAPbI3to the non-perovksiteδ-FAPbI3still occurs in un-doped FAPbI3films owing to the existence of crack defects, which degrads the photovoltaic responses. To investigate the crack ratio (CR)-dependent structure and excitonic characteristics of the polycrystalline FAPbI3thin films deposited on the carboxylic acid functionalized ITO/glass substrates, various spectra and images were measured and analyzed, which can be utilized to make sense of the different devices responses of the resultant perovskite based photovoltaic cells. Our experimental results show that the there is a trade-off between the formations of surface defects and trapped iodide-mediated defects, thereby resulting in an optimal crack density or CR of the un-dopedα-FAPbI3active layer in the range from 4.86% to 9.27%. The decrease in the CR (tensile stress) results in the compressive lattice and thereby trapping the iodides near the PbI6octahedra in the bottom region of the FAPbI3perovskite films. When the CR of the FAPbI3film is 8.47%, the open-circuit voltage (short-circuit current density) of the resultant photovoltaic cells significantly increased from 0.773 V (16.62 mA cm-2) to 0.945 V (18.20 mA cm-2) after 3 d. Our findings help understanding the photovoltaic responses of the FAPbI3perovskite based photovoltaic cells on the different days.

Low-velocity impact response of hybrid sheet moulding compound composite laminates

This work presents a comprehensive study on the impact damage tolerance of Sheet Moulding Compounds (SMCs). The performance of glass, carbon and hybrid glass/carbon SMCs are compared by means of tensile, compression, low-velocity impact and compression after impact experiments. Damage analysis of the impacted laminates was performed by ultrasonic and X-ray methodologies. The glass SMC exhibited the highest damage tolerance in low-velocity impact with the smallest damaged area, crack density and loss in compression after impact (CAI) strength. On the other hand, the carbon SMC demonstrated superior in-plane stiffness and strength, but exhibited a large damaged area and crack density under impact. The hybrid SMC displayed an optimal compromise, exhibiting intermediate tensile in-plane performance and excellent damage tolerance at lower impact energy levels, but suffered from extensive delamination at the highest impact energy. Overall, the findings highlight the suitability of hybrid SMCs for structural applications with potential impact risks.

Crack behaviour and failure mechanisms of air plasma sprayed (Gd, Yb) doped YSZ thermal barrier coatings under oxy-acetylene flame thermal shock

This paper examines the performance and failure mechanisms of atmospheric plasma sprayed (Gd, Yb)-doped YSZ (RYSZ) thermal barrier coatings (TBCs) under oxy-acetylene flame thermal shock conditions. The study involved cyclic thermal shock testing at temperatures of 1400 °C, 1500 °C, and 1600 °C for 10-min intervals until failure occurred, with failure counts recorded as 6, 2, and 2, respectively. During the thermal shock tests, tensile stress in the top coat (TC) caused vertical cracks. The growth of the thermally grown oxide (TGO) layer concentrated stress at the top coat/bond coat interface, leading to transverse interfacial cracks. As the shock temperature increased, the density of vertical cracks and the length of transverse interfacial cracks also increased. Additionally, transverse cracks developed in the TC due to sintering of the surface region at higher shock temperatures. The interaction between vertical and transverse cracks was critical to the spalling of the TC. Variations in crack densities and lengths resulted in different failure modes of the TBCs, depending on the thermal shock temperatures (1400 °C, 1500 °C, and 1600 °C).

High temperature fatigue behavior of coated and uncoated nickel-based single crystal superalloy DD6: Microstructures evolution, damage mechanisms and lifetime prediction

Thermal barrier coatings (TBCs) are widely used to further extend the lifetime of turbine blades by protecting the blades from high temperature corrosion and oxidation. However, the mechanical behavior of turbine blades is obviously affected by the TBCs. In this study, microstructures evolution, damage mechanisms and life prediction of coated and uncoated nickel-based single crystal (NBSX) superalloy DD6 under isothermal fatigue load were investigated at 980 °C. The effects of TBCs on fatigue failure behavior and lifetime of DD6 were addressed. The results showed that the fatigue lifetime reduced with the increase of load. The effect of TBCs on the fatigue lifetime was related to the stress amplitude, as the effect was beneficial at high stress but almost negligible at low stress. Fracture morphologies showed that the cracks more likely initiated and propagated from basal defects for both coated and uncoated DD6, and the microstructure evolution also showed stress amplitude dependence. The crack density of uncoated DD6 increased first and then decreased with the increase of stress amplitude. However, the TBCs reduced the number of cracks that penetrate into the DD6 substrate, and the stress amplitude exerted a significant effect on crack propagation paths. In addition, the rafting behaviors of the DD6 substrate of coated and uncoated samples was compared, and results showed that TBCs could reduce the rafting degree of DD6. Finally, the fatigue lifetime of coated samples was predicted based on the modified Basquin model, and the prediction results fitted well with the experimental results.

Investigation of the dynamic mechanical response of corroded ultra-high performance fiber reinforced concrete (UHPFRC) with initial defects

This study addresses the dynamic mechanical response of the corroded ultra-high-performance fiber-reinforced concrete (UHPFRC) with initial defects, considering the possibility of corrosion deterioration induced by various pre-existing cracks during the long-term service life. For this purpose, an integrated accelerated corrosion method and Split Hopkinson Pressure Bar (SHPB)/high-speed camera etc. techniques are employed. Results show that increasing pre-impacting damage promotes the crack density and maximum width by 32.4%–62.3 % and 1.11–1.8 times, respectively. In terms of mechanical properties, coupling damages of initial defects and corrosion have adverse effects on the dynamic mechanical response. Typical fib Model Code 2010 applies to predict the DIF evolution of the corroded UHPFRC with initial defects. Numerous shear cracks are created at an angle along the weak interface as the corroded specimens with initial defects are again subjected to axial loading, revealing the associated failure mechanism. These results shed light on the dynamic response of corroded UHPFRC containing various initial defects and the failure mechanism gives some reference to service status evaluation.

In-situ acoustic emission investigation of asphalt fracture process and damage quantification for different asphalt mixtures

Abstract The identification of cracking damage and the dynamic diagnosis of damage evolution are of great importance to prolong the service life of asphalt mixture materials. Acoustic emission (AE) can identify the formation and propagation of cracks by detecting the released energy of the damage; therefore, it provides a viable real-time technique to estimate the damage state in the context of structural health monitoring. In this study, the crack formation and propagation of three different asphalt mixtures were investigated using in-situ AE monitoring and microscopy imaging. A three-point bending test was performed using specimens fabricated from three different types of asphalt mixtures. The variation of AE parameters such as the cumulative AE energy and the AE count was obtained and correlated with the crack sizes to characterize the damage process of the three mixtures. Based on the AE parameters, the whole damage process can be divided into three distinct phases, namely, the elastic deformation, damage accumulation, and crack propagation. The AE parameters in the three different mixtures show unique features, and they can be used to capture the transition between phases and identify the damage state. A universal power law model is proposed to correlate the AE energy and the crack density for different types of asphalt mixtures, providing a viable means for damage quantification and predictive maintenance.

Quantitative characterization of granite failure intensity under dynamic disturbance from energy standpoint

Abstract Quantitative evaluation of rock dynamic disaster intensity is a challenging and difficult task in the field of earth science. In this article, the dynamic compression tests of granite under different impact velocities are carried out, and the energy evolution characteristics of the dynamic failure process of granite are analyzed. The dynamic fracture characteristics of granite were studied by using computed tomography and section scanning equipment. The results show that the energy dissipation and energy accumulation mechanism of granite under dynamic loading are fundamentally changed with the increase of impact disturbance strength, which leads to the transformation of the failure mode from the tension-type sheet crack under low-speed impact to the complex network crack coupled by tension and shear under high-speed impact. At the same time, the greater the impact velocity, the larger the macroscopic crack density, the more uneven the particle distribution on the fracture section, the greater the roughness, and the higher the rock mass fracture degree. In accordance with the results, the energy distribution ratio is proposed to quantitatively characterize the coupling effect of energy dissipation and energy accumulation in the dynamic failure process of granite and to reflect its dynamic failure intensity. The higher the energy distribution ratio, the stronger the energy coupling effect and the more intense the dynamic failure of the rock mass.