Crack Initiation Research Articles

Strain Distribution and Its Relationship to Crack Initiation and Propagation Behavior During Cyclic Bending Test on Commercial SUS301 Sheet

Strain Distribution and Its Relationship to Crack Initiation and Propagation Behavior During Cyclic Bending Test on Commercial SUS301 Sheet

A FEM-based model for failure initiation in the microstructure of gray cast iron under uniaxial compression

PurposeThe purpose of this study was to validate the feasibility of the proposed microstructure-based model by comparing the simulation results with experimental data. The study also aimed to investigate the relationship between the orientation of graphite flakes and the failure behavior of the material under compressive loads as well as the effect of image size on the accuracy of stress–strain behavior predictions.Design/methodology/approachThis paper presents a microstructure-based model that utilizes the finite element method (FEM) combined with representative volume elements (RVE) to simulate the hardening and failure behavior of ferrite-pearlite matrix gray cast iron under uniaxial loading conditions. The material was first analyzed using optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) to identify the different phases and their characteristics. High-resolution SEM images of the undeformed material microstructure were then converted into finite element meshes using OOF2 software. The Johnson–Cook (J–C) model, along with a damage model, was employed in Abaqus FEA software to estimate the elastic and elastoplastic behavior under assumed plane stress conditions.FindingsThe findings indicate that crack initiation and propagation in gray cast iron begin at the interface between graphite particles and the pearlitic matrix, with microcrack networks extending into the metal matrix, eventually coalescing to cause material failure. The ferritic phase within the material contributes some ductility, thereby delaying crack initiation.Originality/valueThis study introduces a novel approach by integrating microstructural analysis with FEM and RVE techniques to accurately model the hardening and failure behavior of gray cast iron under uniaxial loading. The incorporation of high-resolution SEM images into finite element meshes, combined with the J–C model and damage assessment in Abaqus, provides a comprehensive method for predicting material performance. This approach enhances the understanding of the microstructural influences on crack initiation and propagation, offering valuable insights for improving the design and durability of gray cast iron components.

Dielectric Hybrid Optimization Model Based on Crack Damage in Semi-Rigid Base Course

To accurately predict the relative permittivity of cement-stabilized base materials, a study on the dielectric mixing model for cracked base materials was conducted. Based on the electromagnetic mixing theory of multiphase composites, a comprehensive dielectric mixing model of cement-stabilized base materials was derived. The volume ratios and relative permittivity values of the specimen constituents in different cracking states of the cement-stabilized base were determined using industrial CT and a Percometer relative permittivity meter, with comprehensive consideration given to the effects of different initial porosities and crack widths on the dielectric properties. Based on the volumetric and dielectric properties of the base material specimens in both intact and cracked states, as well as the error analysis between the predicted and measured values of the relative permittivity constant, the u-optimal solution of the dielectric mixing model for cement-stabilized base material was determined to be 1. Consequently, an optimization dielectric mixing model for semi-rigid base course materials in a cracked state was developed. The optimization model proposed is suitable for predicting the dielectric properties of cement-stabilized base material with crack widths generally greater than 3 mm during the service life of semi-rigid base course in engineering practice.

Numerical Study on the Determination of Crack Initiation Angle, Stress Field and Stress Triaxiality at Crack Tip in a Cracked Beam of Functionally Graded Material

Numerical Study on the Determination of Crack Initiation Angle, Stress Field and Stress Triaxiality at Crack Tip in a Cracked Beam of Functionally Graded Material

Insights into the Influence of Tensile and Compressive Strain on the Microstructure and Corrosion Performance of 304 L Stainless Steel

The effects of tensile and compressive strain, originating from U-bent deformation, on the corrosion behavior of 304 L stainless steel were studied via analyses of the material’s microstructure and electrochemistry in a 3.5% NaCl solution. In contrast with the as-received 304 L steel with the largest grain size, the deformed 304 L material with a small grain size had the lowest number of Σ3 grain boundaries and an overall low fraction, with special low-Σ values (≤29). Moreover, the dislocation density increased to 1.13 × 1016/m2 and 1.4 × 1016/m2 for the tensile and compressive 304 L steel testing, respectively. The decrease in Epit and increase in ipit suggested that there was a decrease in anti-corrosion properties due to tensile and compressive deformation. This might be attributed to the higher plastic strain found in deformed 304 L steel, which can induce the rupture of passive film and have a harmful influence on corrosion resistance. In particular, the compressive 304 L steel with the highest content of deformed grains (42.12%) promoted the formation of microgalvanic cells, thereby facilitating the nucleation of pits. Then, these pits grew to a large size through grain shedding. Subsequently, massive chloride ions were generated during metal dissolution and diffused along grain boundaries, which promoted the initiation and propagation of intergranular corrosion cracks.

A numerical investigation of the structural behavior of reinforced concrete beams fully or partially encased with UHPC layers in flexure

Weakness in the structural facilities appears due to design faults, poor construction, usage change, maintenance lack, material defects, and environmental conditions. Therefore, strengthening structures becomes necessary for deteriorated concrete and enhancing aging concrete elements to achieve satisfactory performance perfectly. This study numerically investigated the structural behavior of conventional concrete beams reinforced with Ultra-High Performance Concrete (UHPC) layers on different sides. The arrangement of UHPC layers, bonding method between traditional concrete and UHPC, layer thickness, and reinforcement ratio were examined using Abaqus software. The interface between the UHPC layer and conventional concrete sustains compressive, tensile, and shear stresses, which cause weak resistance to the stresses at the contact surfaces. Therefore, the simulation of contact face in Abaqus needs a proper numerical model relying on practical methods. However, using the bonding models available in Abaqus is crucial for reaching logical results comparable to the practical ones. The practical bonding approaches are highly consequential, such as roughening surfaces by sandblasting to attain a firm connection between the contact surfaces, which permits using a surface-based tie constraint for simulation. Further, epoxy resin conducts as a thin coating between contact surfaces, making it possible to simulate via a cohesive surface. The results proved that increasing the area encased by the UHPC layer improves load capacity further and reduces the deflection at the maximum load. Surrounding the beam on whole sides with a UHPC raises load capacity by 108 % and reduces deflection by 46 %. Adding a UHPC layer to the beam delays crack initiation and reduces their number and spacing. Increasing the UHPC layer thickness or reinforcement ratio enhances the load capacity of the beam at cracking and the ultimate state.

A novel 'stop-hole' strategy to extend the fatigue life of orthodontic thermoformed retainers: an in vitro study.

This study aimed to investigate the potential to limit crack propagation in thermoformed retainers (TRs) and extend their fatigue life by placing a 'stop-hole'. Thirty-two TRs, fabricated from 1mm thick, round polyethylene terephthalate glycol (PETG) blanks of ICONIC®, underwent testing within a custom-built fatigue tester. After initial crack growth of 3mm, the TRs were divided into three groups: a control group (C) and two experimental groups based on the stop-hole placement method. In the first experimental group, stop-holes were placed using a 1mm round carbide bur on a slow-speed handpiece (ES), while the second group utilized a heated 1-mm-width ball-ended CPITN probe (EH). Following the placement of a stop-hole at the crack-tip, all 32 TRs resumed testing until the final crack length of 10mm was reached. Stop-hole placement significantly prolonged the delay in crack re-initiation in both experimental groups compared to the control group (P < .001 for both). The mean re-initiation times for the ES and EH groups were 104.50 and 129.50min, respectively, whereas the control group was 28.94min. Consequently, this discrepancy was reflected in the total testing times, with both experimental groups requiring significantly longer time to reach the final crack length (P < .001). There was no significant difference in the testing times between the two experimental groups. This is an in vitro study. The stop-hole methodology significantly extended the fatigue life of a TR in a controlled laboratory environment.

Fracture Characteristics and Tensile Strength Prediction of Rock–Concrete Composite Discs Under Radial Compression

To investigate the fracture mechanism of rock–concrete (R–C) systems with an interface crack, Brazilian splitting tests were conducted, with a focus on understanding the influence of the interface crack angle on failure patterns, energy evolution, and RA/AF characteristics. The study addresses a critical issue in rock–concrete structures, particularly how crack propagation differs with varying crack angles, which has direct implications for structural integrity. The experimental results show that the failure paths in R–C disc specimens are highly dependent on the interface crack angle. For crack angles of 0°, 15°, 30°, and 45°, cracks initiate from the tips of the interface crack and propagate toward the loading ends. However, for angles of 60°, 75°, and 90°, crack initiation shifts away from the interface crack tips. The AE parameters RA (rise time/amplitude) and AF (average frequency) were used to characterize different failure patterns, while energy evolution analysis revealed that the highest percentage of energy consumption occurs at a crack angle of 45°, indicating intense microcrack activity. Moreover, a novel tensile strength prediction model, incorporating macro–micro damage interactions caused by both microcracks and macrocracks, was developed to explain the failure mechanisms in R–C specimens under radial compression. The model was validated through experimental results, demonstrating its potential for predicting failure behavior in R–C systems. This study offers insights into the fracture mechanics of R–C structures, advancing the understanding of their failure mechanisms and providing a reliable model for tensile strength prediction.

Predicting fatigue crack initiation life in typical joints of offshore observation tower structures

ABSTRACT Tubular structures are widely used in steel constructions, such as offshore platforms, because of their superior mechanical qualities, efficient use of materials, lightweight and aesthetically pleasing appearance. The most common failure mode of offshore tubular joints is fatigue damage brought on by cyclic loading during the course of their service life, like wind, wave and equipment vibration. In this paper, the finite element model of the TK-type tubular joint at the stress concentration position is established by analyzing the load and response of the observation tower. The continuum damage mechanics method has been used to evaluate the fatigue crack initiation position and life of the tubular joint, and the crack initiation life of the key nodes has been predicted, which provides theoretical support for ensuring the service safety of the offshore observation tower.

Assessment of multiaxially loaded safety components with uniaxial stress state in fatigue critical sites caused by design

AbstractThe focus of this study, using results obtained with hollow specimens of the alloy Al 2024 T3 (AlCuMg2 T3) with a one‐sided bore, was to determine if, under multiaxial loading, the fatigue strength in a notch with a uniaxial stress state can simply be assessed without the application of any multiaxial strength hypothesis. In the fatigue critical location, the bore edge, only a superimposition of normal stress components, resulting from axial loading or/and torsion, occurs. In the case of out‐of‐phase loading, the resulting local uniaxial stress is even lower than the stress under in‐phase loading and leads to an increase of fatigue life to crack initiation under the non‐proportional loading, which is not observed in the case of multiaxial stressing/straining of the material itself. As the local stress state in the crack initiation site is uniaxial, the application of a multiaxial strength hypothesis, for the failure criterion of crack initiation (l=0.2 mm), is not necessary. Furthermore, the benefit of non‐homogenous stress distributions, which allow locally higher stresses than the levels given by the Woehler‐line for unnotched specimens, was underlined by considering highly‐stressed, material‐volume‐related support factors.

Stress Concentration Modelling in Internal Stiffeners of Ship-to-Shore Quay Cranes Legs Due to Structural Heightening

This paper presents a study on the modelling and estimation of stress concentration at the tips of leg stiffeners in ship-to-shore (STS) quay cranes, which is intensified in those on the sea-side leg extensions, which are more prone to crack formation, notably following structural heightening of the cranes. A computer-simulated database was generated, incorporating mechanical parameters and geometric features that impact stress concentration. These variables can then be integrated as inputs into a multiple linear regression model (MLR). This methodology offers an alternative to the finite element method (FEM) for the computation of stress concentration and deformations. At the same time, the statistical significance of the parameters influencing this scenario is determined, ensuring a comprehensive assessment of their impact on the studied phenomenon. The research underscores the importance of incorporating stress concentration and structural geometry considerations into crane design or modification, given their crucial role in preserving the remaining lifecycle of the structure. Crack initiation is significantly intensified in regions characterised by high stress concentrations, particularly in areas where there are geometric changes at the tips of the stiffeners, where local stiffness is altered. All of this is in combination with work cycles under the supported loads.

Relationship between the microstructural energy release rate of cortical bone and age under compression condition

Most studies evaluated the energy release rate of cortical bone macrostructure under Mode I, Mode II, and mixed Mode I-II loading conditions. However, testing the macrostructural energy release rate requires an initial crack and recording the applied load and the corresponding crack length in real-time, which may introduce measurement errors and differences with the actual fracture scenarios. To further understand how the energy release rate contributed to the cortical bone fracture characteristics, this study predicted the microstructural energy release rate of cortical bone and then investigated its age-related varitions. The microstructural energy release rate of femoral cortical bone in rats from different ages was back-calculated by fitting the experimental and simulated load–displacement curves under compression load. The trends in the microstructural energy release rate were revealed, and the underlying reasons for the age-related changes were investigated by integrating the discussion on the cortical bone mechanical parameters at various levels obtained from the previous experiment. The predicted microstructural energy release rate of femoral cortical bone in the rats from 1, 3, 5, 7, 9, 11, and 15 months of age were in the range of 0.08–0.12, 0.12–0.14, 0.15–0.19, 0.25–0.28, 0.23–0.25, 0.19–0.22, and 0.13–0.16 N/mm, respectively. The statistical analyses showed the significant differences in the microstructural energy release rate at different ages. The results indicated an increasing trend followed by a decrease from 1 to 15 months of age, and the correlations between microstructural energy release rate and age were significant. The age-related variations in the microstructural energy release rate may be linked to the changes in the microarchitecture, and the fracture load is influenced by the micro-level mechanical parameters. Notably, the age-related trends in microarchitecture and energy release rate were similar. These findings were valuable for understanding the mechanism underlying the weakening mechanical properties of cortical bone microstructure with age from an energy perspective.

Influence of the longitudinal welded joint microstructure of X52 and X70 large diameter pipes on resistance to hydrogen embrittlement

The article covers influence of a set of gradient microstructures of large diameter pipes (LDP) on resistance to hydrogen embrittlement. The object of the study were specimens of longitudinal welded joints of X52 and X70 LDP before and after slow strain rate tensile tests (SSRT) in gaseous nitrogen and hydrogen. It was found that fracture of X52 specimens during SSRT occurred with multiple crack initiation centres at the interfaces of the pearlite–ferrite structural constituents, while fracture of X70 specimens resulted in a single crack propagation. Steels Х52 and Х70 fractured not in the heat-affected zone (HAZ) recrystallisation area containing islands of martensite-austenite phase, but in the high-temperature tempering zone, which is characterised by anisotropic ferrite-perlite (Х52) and ferrite-bainite (Х70) microstructure. Finely dispersed uniform structure of bainite ferrite despite the content of martensite-austenite component is not a source of hydrogen crack initiation. Although a welded joint of X70 steel is characterised by higher strength, it is less susceptible to the embrittlement effects of gaseous hydrogen than X52, which is probably due to the finer and more uniform structure of X70 steel. Presence of ferrite-pearlite banding in the structure of X52 steel has a more negative effect on resistance to hydrogen embrittlement than increased hardness of the HAZ high-temperature tempering area of X70 steel.

How does turbulence intensity affect the fatigue life of composite airfoils based on existing CFD and experimental data?

This research investigates the effect of airflow turbulence intensity on the fatigue life of composite airfoil structures in aerospace engineering. Using advanced Computational Fluid Dynamics (CFD) simulations, this study provides a comprehensive analysis of how varying levels of turbulence intensity—ranging from mild (5%) to severe (30%)—impact the mechanical degradation and fatigue performance of carbon-fiber-reinforced polymers (CFRPs) used in airfoil designs. The research quantifies the relationship between turbulence levels and changes in stress distribution, highlighting critical points of fatigue crack initiation and subsequent propagation. The study includes detailed comparisons of CFD results to experimental data to validate the predictive models and discusses how localized stress fluctuations under high-intensity turbulence accelerate the onset of fatigue failure. We present significant findings that demonstrate a non-linear relationship between turbulence intensity and the reduction in fatigue life, suggesting optimal design modifications for enhanced durability. Furthermore, this paper explores current challenges in merging CFD data with real-world fatigue testing and proposes advanced techniques such as adaptive mesh refinement and hybrid simulation models to improve predictive accuracy and computational efficiency in future research.

Experimental analysis of glass failure criteria under different thermal conditions

The initiation of the first crack mainly determines the criteria for glass failure. However, the extended consequences of cracking, with the formation of multiple cracks merging, result in fallout conditions under varying thermal loads that become more critical. Point-supported glass arrangements are globally used in high-rise and energy-efficient buildings for architectural ingenuity aimed at a low budget. However, the formation of cracks due to thermal load resulting in glass breakage could infuriate the overall fire dynamics of the enclosed area. Therefore, experimental study and prediction of glass failure become very crucial. The present experimental study focuses on finding the most critical parameter that may quantify the cause of glass failure and further breakage in fallout conditions under varying thermal loads. 45 experiments were carried out on float glass of 300 × 300 mm2 with 4 mm, 6 mm, 8 mm, 10 mm, and 12 mm with continuous fuel supply arrangements. Critical parameters analysed were the time of crack initiation, glass temperature at the time of cracking, maximum temperature difference at glass failure, and thermal strain caused by the temperature difference on the glass surface. The range of minimum and maximum temperature difference recorded on the glass surface for the present study was between 30–35°C and 55–60°C at the breakage time for all the experiments. The Maximum temperature difference measured was 56.99°C on the 12 mm glass surface, and the corresponding maximum thermal strain found was 482 × 10−6 mm/mm. The maximum heat release rate was found to be approximately 200 kW. Maximum heat flux was found in the range of 10.33 kW/m2 to 21.14 kW/m2. A correlation was also developed using the least square method for all the thicknesses, which is well correlated with the glass thickness per unit length.

AI-Enhanced Prediction of Pavement Crack Propagation: A Study Using Traffic Load, Environmental and Material Data

This study develops an AI-based predictive model for forecasting pavement crack propagation by integrating traffic load, environmental conditions, and material property data. Traditional pavement management systems often struggle to accurately predict crack growth due to the complex interactions between these influencing factors. By leveraging data from various sources, including sensor-based traffic metrics, meteorological data, and material composition tests, this study identifies significant variables contributing to crack initiation and progression. The proposed model utilizes a blend of machine learning algorithms, including Random Forest and neural networks, with a cross-validation approach to ensure robustness. Results indicate that the model achieves high prediction accuracy, with an RMSE of 1.2 mm/year and an R-squared value close to 0.93. The findings support the use of AI-enhanced models as reliable tools for road infrastructure planning and maintenance, promising reductions in maintenance costs and improved pavement durability.

The Anti/Deicing Performance of the Low Interfacial Toughness Coating Is Enhanced: Induced Ice Crack Generation and Its Extension.

The low interfacial toughness of the material surface is important for crack initiation and expansion of the ice layer as it remains an effective method for large-scale deicing. However, there are challenges, such as a large critical icing size and incomplete shedding of the ice layer. Adjusting the interfacial forces to make the ice more prone to cracking, expanding, and shedding is advantageous in addressing the problem of anti-icing failure in materials with low interfacial toughness. Therefore, we propose a deicing strategy that combines porous PDMS (polydimethylsiloxane) coatings with low interfacial toughness and piezoelectric vibration. A series of hydrophobic porous PDMS coatings with different porosities were prepared on the surface of an aluminum alloy substrate through curing and phase separation. The elastic modulus of the coatings decreased from 1465 to 509 kPa as the coating porosity increased, revealing the mechanism behind the improvement in mechanical properties. The key to promoting ice fracture on porous PDMS coatings lies in the synergistic effect of the out-of-plane shear stress and microcracks at the solid-ice interface. This work focuses on exploring the characteristics of interfacial forces by combining the intrinsic mechanical properties of coatings with external forces, providing new insights for designing low interfacial toughness anti-icing materials.

Increasing accuracy in predicting mode I fracture toughness of rock structures: a comparative analysis of the rock engineering system method

The investigation of crack initiation and expansion is vital for the stability of structures. The Mode I fracture toughness (KIc) of rocks is a key property used to predict crack propagation in tension and hydraulic fracturing. Various methods have been introduced to determine KIc, but results differ due to factors like sample dimensions, crack geometry, groove type, and loading conditions. The cracked chevron notched Brazilian disc (CCNBD) sample is commonly used in laboratory tests for its easy preparation. This study employs the rock engineering system (RES) technique to overcome the challenges of time-consuming and costly laboratory tests and the uncertainty in traditional methods (analytical, numerical, experimental, laboratory, regression). Using 88 CCNBD rock samples proposed by ISRM, input parameters include thickness of the disc specimen (B), uniaxial tensile strength (σt), initial crack length (α0), radius of the disc specimen (R), crack length (αB), and the length of the final crack (α1). The RES-based model used 70 data points (80% of the dataset) for development, and 18 data points (20%) for evaluation. Regression analysis compared the performance of the RES method, using statistical indicators such as squared correlation coefficient (R2), mean square error (MSE), and root mean square error (RMSE) to measure accuracy. The RES-based method outperformed other regression techniques, demonstrating significantly enhanced accuracy. This highlights the effectiveness and superior performance of the RES method in estimating fracture toughness, particularly for CCNBD samples, showcasing its potential as a robust analytical tool.

Fracture Toughness of Ordinary Plain Concrete Under Three-Point Bending Based on Double-K and Boundary Effect Fracture Models.

Fracture tests are a necessary means to obtain the fracture properties of concrete, which are crucial material parameters for the fracture analysis of concrete structures. This study aims to fill the gap of insufficient test results on the fracture toughness of widely used ordinary C40~C60 concrete. A three-point bending fracture test was conducted on 28 plain concrete and 6 reinforced concrete single-edge notched beam specimens with various depths of prefabricated notches. The results are reported, including the failure pattern, crack initiation load, peak load, and complete load versus crack mouth opening displacement curves. The cracking load showed significant variation due to differences in notch prefabrication and aggregate distribution, while the peak load decreased nonlinearly with an increase in the notch-to-height ratio. The reinforced concrete beams showed a significantly higher peak load than the plain concrete beams, attributed to the restraint of steel reinforcement, but the measured cracking load was comparable. A compliance versus notch-to-height ratio curve was derived for future applications, such as estimating crack length in crack growth rate tests. Finally, fracture toughness was determined based on the double-K fracture model and the boundary effect model. The average fracture toughness value for C50 concrete from this study was 2.0 MPa·m, slightly smaller than that of lower-strength concrete, indicating the strength and ductility dependency of concrete fracture toughness. The fracture toughness calculated from the two models is consistent, and both methods employ a closed-form solution and are practical to use. The derived fracture toughness was insensitive to the discrete parameters in the boundary effect model. The insights gained from this study significantly contribute to our understanding of the fracture toughness properties of ordinary structural concrete, highlighting its potential to shape future studies and applications in the field.

Role of inclusion clusters on fatigue crack initiation in powder metallurgy nickel-based FGH96 superalloy

Inclusion clusters with a size of several tens of micrometers were found to be inclined to early crack initiation, resulting in an abnormally reduced fatigue life. Fatigue tests were conducted to elucidate crack initiation behaviors of inclusion clusters in nickel-based powder metallurgy (P/M) FGH96 superalloy. The inclusion clusters with varying sizes and shapes located at grain boundaries are composed of Al2O3, MgO and ZrO2 particles. The inclusion cluster with large size within 25-35 μm, small average particle distance within 0-4 μm and large orientation relative to loading direction within 35-66° will be more likely to cause crack initiation. In particular, the inclusion clusters with large size and high aggregation degree experience extruding during processing and subsequent heat-treatments due to the difference in thermal expansion coefficient with the matrix behave multiple cracking before fatigue loading, thereby facilitating crack initiation in the surrounding matrix grains. Moreover, as the main cracking part of inclusion clusters, the Al2O3 particles exhibit self-cracking and interface debonding, owing to higher hardness and poorer deformation coordination degree with matrix compared to other component inclusion particles.