Crack Initiation Research Articles

Evaluation on the diffusion-fusion properties and interfacial mechanical behavior of virgin and aged asphalt

To investigate the regeneration mechanisms of rejuvenated asphalt mixtures, molecular simulation techniques were employed to research virgin and aged asphalt's fusion characteristics and interface mechanical properties. The blended zone was identified based on relative density distribution, and a molecular-scale calculation method for the Degree of binder Blended (DOB) between virgin and aged asphalt was proposed. Finally, the influence of DOB on the mechanical properties of the asphalt-aggregate interface was evaluated through interface pull-out tests. The results revealed that the proposed molecular-scale DOB calculation method effectively assessed the blending effectiveness between virgin and aged asphalt. Higher degrees of asphalt aging made it more challenging for aged asphalt to fuse with virgin asphalt, while elevated temperatures facilitated diffusion fusion between them. Under tensile loading, initial cracks were primarily initiated from the rejuvenated asphalt's blended zone. This region represented the weakest area within the interface system and was prone to fracture under load. The increase in DOB significantly improved the interfacial properties of recycled asphalt, with the increase in DOB the interfacial tensile strength increased by 4%–14% and the fracture energy increased by 10%–19%. However, this enhancement effect diminished with an increased degree of asphalt aging. At the molecular scale, increasing DOB improved the interface strength and deformation resistance of rejuvenated asphalt. The molecular simulation results provide theoretical guidance for evaluating the fusion degree of aged asphalt in RAP materials and determining the utilization efficiency of aged asphalt.

Effects of coarse aggregate size on thickness and micro-properties of ITZ and the mechanical properties of concrete

This research delves into the impact of coarse aggregate particle size on the mechanical properties of concrete. Nano-indentation and scanning electron microscope (SEM) techniques were applied to characterize the micro-properties and thickness the Interfacial Transition Zone (ITZ). The effect of coarse aggregate size on concrete's compressive strength (σc) and elastic modulus (E) and the relationship between the micro properties of the ITZ and the macro properties of concrete were discussed. In addition, Griffith's microcrack theory was adopted to explain related mechanisms. The relationship between the microscopic properties of the ITZ and the macroscopic properties of concrete was discussed. The results show that, in concrete with a low water cement-ratio w/c (0.3), thickness of ITZ increased with the coarse aggregate size and concrete properties decreased. While, in concrete with a higher w/c (0.4), there exists an optimum coarse aggregate size for the lowest thickness of ITZ and highest strength. Taking the ITZ as the initial crack in concrete failure, concrete properties can be linked to ITZ thickness from Griffith's microcrack theory.

Novel integration of PSO-enhanced damage mechanics and finite element method for predicting medium–low-cycle fatigue life in perforated structures

In this research, we introduce an innovative approach that combines the Continuum Damage Mechanics-Finite Element Method (CDM-FEM) with the Particle Swarm Optimization (PSO)-based technique, to predict the Medium-Low-Cycle Fatigue (MLCF) life of perforated structures. First, fatigue tests are carried out on three center-perforated structures, aiming to assess their fatigue life under various strengthening conditions. These tests reveal significant variations in fatigue life, accompanied by an examination of crack initiation through the analysis of fatigue fracture surfaces. Second, an innovative fatigue life prediction methodology is applied to perforated structures, which not only forecasts the initiation of fatigue cracks but also traces the progression of damage within these structures. It leverages an elastoplastic constitutive model integrated with damage and a damage evolution model under cyclic loads. The accuracy of this approach is validated by comparison with test results, falling within the three times error band. Finally, we explore the impact of various strengthening techniques, including cross-sectional reinforcement and cold expansion, on the fatigue life and damage evolution of these structures. This is achieved through an in-depth comparative analysis of both experimental data and computational predictions, which provides valuable insights into the behavior of perforated structures under fatigue conditions in practical applications.

Enhanced hot corrosion resistance of AlCoCrFeNi2.1 high entropy alloy coatings by extreme high-speed laser cladding

Extreme high-speed laser cladding (EHLC) and multiple laser remelting (EHLC-MR) are used to improve hot corrosion resistance of AlCoCrFeNi2.1 eutectic high-entropy alloy (EHEA) coatings by refining their microstructures, introducing low angle grain boundaries (LAGBs) and high densities of dislocations as well as higher compressive residual stresses (CRSs) in the coatings. The experimental results show that finer microstructure, more LAGBs and high densities of dislocations are beneficial to increase Al2O3 nucleation sites and promote the uniform formation of the oxide layer on the coating surface. On the other hand, higher CRSs suppress the initiation and propagation of cracks as well as enhance the adhesion between the oxide layer and the substrate. Thus the hot corrosion resistance of the EHEA coatings under a molten salt of 75% Na2SO4 + 25% NaCl at 900°C is improved significantly. These novel results provide effective approach for designing elevated-temperature materials.

Effect of loading rate on local deformation of rock-like models with locked segment

To investigate the influence of loading rate on the local deformation and failure characteristics of rock-like models with a locked segment, this study fabricated them using quartz sand and barite powder as aggregates, and gypsum as cementing material. Uniaxial compression tests, combined with strain cube monitoring and the digital image correlation technique, were employed to analyze the mechanical properties, internal and external deformation characteristics, crack propagation, and failure modes at different loading rates. The results showed that as the loading rate increased, the strength of these models initially increased significantly and then slightly decreased, primarily due to the complex interaction between the longitudinal and transverse deformations of the models and the stress concentration intensity at the crack tips. The fluctuation in the principal strain axis's deflection angle revealed the complex process of stress wave propagation and particle adjustment within the models, with more pronounced fluctuations observed at higher loading rates. The stress intensity factors, KIand KII, at the crack tips first increased and then decreased with increasing loading rate, with KI consistently higher than KII. The strain concentration phenomenon in the rock-like models occurred earlier with increasing loading rates, and the corresponding crack closure stress exhibited a decreasing trend. Higher loading rates caused earlier crack initiation and faster propagation. As the loading rate increased, the crack paths shortened, and both damage density and severity increased significantly, indicating brittle failure. This study provides important experimental evidence and theoretical support for understanding the effects of loading rate in rock mass engineering.

A Monte-Carlo approach for crack initiation modeling of cast superalloys informed by crystal plasticity

Crystal plasticity simulations of materials to assess the fatigue response on the microscale are becoming increasingly popular in industrial application. However, in the case of parts made from cast Ni-base superalloys, the amount of pores in a part combined with the fine spatial discretization around the pores needed due to strong mechanical gradients quickly leads to a computationally impractical number of mesh elements. In this paper we show an alternative to explicit crystal plasticity modeling of part-scale porosity by introducing a Monte-Carlo submodel that recombines the fatigue response of single pores predicted by crystal plasticity into the fatigue response of the pore agglomerate. The model can be applied in realtime due to the use of precomputed crystal plasticity results. We demonstrate that fatigue indicator parameters predicted by the Monte-Carlo submodel agree well with those predicted by explicit crystal plasticity simulations. Lastly, we apply the proposed model to study the influence of different porosity volume percentages, pore sizes and pore morphologies on the fatigue indicator parameters of a cast MAR-M247 superalloy.

Mechanical properties and damage constitutive relationship of microwave irradiation of granite under uniaxial compression

Microwaves have great potential to increase the efficiency of hard rock breakage during mechanical excavation in engineering. This study conducted uniaxial compression tests on granite specimens after microwave irradiation at 4.85 kW. The results demonstrated a linear decrease in uniaxial compressive strength and elastic modulus correlating with increasing irradiation durations. Acoustic emission data indicated increased normalized crack closure stress and decreased normalized crack initiation and damage stress, suggesting complex crack propagation and evolution patterns under microwave influence. 3D Digital Image Correlation revealed that as heating time increased, the macrocrack leading to specimen failure shifted from being load-dominated to involving both load and microwave-induced thermal cracks. A simple four-parameter damage constitutive model for granite (a 1, r 1 , a 2, and r 2) effectively described the damage evolution under the coupling effect of microwave and uniaxial load. The model accurately characterized the complete stress–strain curves, including both microcrack compaction and post-peak stages, revealing that initial damage escalates with longer heating, though the progression rate decreases.

Discontinuity-enhanced icephobic surfaces for low ice adhesion

HypothesisPassive low ice-adhesion surfaces are frequently composed of soft materials; however, soft materials potentially present durability issues, which could be overcome by fabricating composite surfaces with patterned rigid and soft areas. Here we propose the innovative concept of discontinuity-enhanced icephobic surfaces, where the stress concentration at the edge between rigid and soft areas, i.e. where discontinuities in elasticity are located, facilitates ice detachment. ExperimentsComposite model surfaces were fabricated with controlled rigid-soft ratios and discontinuity line lengths. The ice adhesion values were measured while recording the ice/substrate interface, to unravel the underpinning ice detachment mechanism. The experiments were complemented by numerical simulations that provided a better understanding of the ice detachment mechanism. FindingsIt was found that when a surface contains rigid and soft areas, stress is concentrated at the edge between soft and hard areas, i.e. at the discontinuity line, rather than all over the soft or rigid areas. An unexpected non-unidirectional crack propagation was observed for the first time and elucidated. When rigid and deformable materials are present, the crack occurs on the discontinuity line and propagates first on rigid and then on soft areas. Moreover, it was demonstrated that an increase in discontinuities promotes crack initiation and leads to a reduction of ice adhesion.

Residual stress induced granular bright facets around inclusions in high-strength steels under high-cycle fatigue

Granular bright facets (GBFs) are frequently observed adjacent to inclusions and within fish-eye areas in the fatigue fractures of high-strength steels under very-high-cycle fatigue (VHCF), considered as a characteristic fracture feature of VHCF. Previous understanding on GBF formation emphasizes the occurrence of nanocystallization in microstructure. In this study, however, the same morphology can also be observed under high-cycle fatigue (HCF). GBF, although closer to fatigue crack initiator and experiencing more stress cycles than the peripheral part of fish-eye (PPFE), exhibits rougher surface morphology in the absence of accumulated plastic strain in microstructure, manifesting relieved crack surface wear. This indicates that the traditional theories on GBF formation for VHCF becomes invalid for HCF. The root cause for GBF formation under HCF is analyzed to be the presence of residual stress around inclusions, which reduces the contact pressure of fatigue crack surfaces inducing wear relief. Accordingly, an analytical model capable of predicting GBF thickness with the effects of HCF conditions and steel properties taken into consideration is established. The model yields accurate predictions of GBF thickness with various loading stresses and inclusion diameters, validated by experimental observations. This study provides theoretical guidance for HCF fracture analysis and fatigue life prediction.

Fracturing Processes in Specimens with Internal vs. Throughgoing Flaws: An Experimental Study Using 3D Printed Materials

AbstractThe fracturing behavior and associated mechanical characterization of rocks are important for many applications in the fields of civil, mining, geothermal, and petroleum engineering. Laboratory testing of rocks plays a major role in understanding the underlying processes that occur on the larger scale and for predicting rock behavior. Fracturing research requires well-defined and consistent boundary conditions. Consequently, the testing design and setup can greatly influence the results. In this study, a comprehensive experimental program using an artificial material was carried out to systematically evaluate the effects of different parameters in rock testing under uniaxial compression. The parameters include compression platen type, specimen centering, loading control method, boundary constraints, and flaw parameters. The results show that these testing conditions have a significant effect on the mechanical behavior of rocks. Using a fixed compression platen helped reduce bulging of the material. Centering of the specimen played a critical role to avoid buckling and unequal distribution of stress. Slower displacement rates can control the energy being released once failure occurs to prevent the specimen from exploding. Also, the frictional end effects were investigated by comparing friction-reduced and non-friction-reduced end conditions. Very importantly, the study also identified variations in crack initiation and propagation between specimens with internal flaws and specimens with throughgoing flaws. This investigation showed that wing cracks appeared in specimens with throughgoing flaws, while wing cracks with petal cracks were associated with the internal flaws. It also showed that the mechanical properties are influenced by the inclination of the flaws and established that specimens with internal flaws generally exhibit higher strength compared to specimens with throughgoing flaws. The systematic analysis presented in this work sheds light on important considerations that need to be taken into account when conducting fracture research and adds knowledge to the fundamental understanding of how fractures occur in nature.

Fracture mechanism and ductility performances of fiber reinforced shotcrete under flexural loading insights from digital image correlation (DIC)

This paper investigates the fracture mechanism and ductility performance of fiber-reinforced shotcrete (FRS) under flexural loading through digital image correlation (DIC) analysis. The focus is on determining the optimal mix design, utilizing recycled and manufactured fibers in shotcrete through four-point bending tests. These tests reveal significant improvements in flexural strength and ductility, as well as crack resistance, attributed to the synergistic effect of both types of fiber in hybrid fiber reinforcement. Notably, the inclusion of recycled fibers from automobile tires enhances mechanical characteristics and impact resistance, contributing to environmental sustainability and cost reduction. DIC analysis offers crucial insights into crack initiation and propagation in shotcrete, highlighting the impact of fiber reinforcement on crack patterns. Manufactured fibers delay crack onset effectively, while hybridization enhances fracture characteristics, offering improved crack control and flexural strength. The study underscores the potential of hybrid fiber mixes for enhancing structural performance in tunnel support applications, emphasizing the synergistic effect of hybrid of different fiber types. Overall, the research contributes to advancing understanding of fracture behavior in fiber-reinforced shotcrete and provides practical insights for optimizing mix designs to achieve superior mechanical properties and durability.

The influence of steep faults at various avoidance distances on the stability of hard rock caverns: Physical model experiments and DEM simulations

The influence of avoidance distances from steep faults on the stability of hard rock caverns is pivotal in deep engineering, yet research in this area remains scant. This study constructed 10 physical models of granite caverns, incorporating artificial cement-filled faults at various avoidance distances ranging from 0 to 2.4 cavern diameters. Biaxial compression experiments were conducted, utilizing acoustic emission and digital image correlation techniques for monitoring. Coupled with discrete element method simulations, the analysis explored the influence mechanisms of fault-cavern distance on the failure modes of hard rock caverns. The results reveal a positive correlation between the peak strength of specimens and fault-cavern distance. As the distance approaches 0.6 cavern diameters, the fault significantly influences the displacement field, crack number, distribution, and crack initiation location within the specimens. Furthermore, even at 1.2 cavern diameters, the fault still exhibits a notable influence on the stress field, external load transfer paths, cavern failure modes, and the size distribution of spalling debris. These findings can guide the selection of sites for deep hard rock caverns, ensuring a minimum fault-cavern distance of 1.2 cavern diameters to mitigate the risks posed by steep faults to such caverns.

Shear behavior of reinforced concrete walls under variable axial tension‐compression and cyclic lateral loads

AbstractUnder a strong earthquake, the axial force of shear walls in tall buildings may vary from compression to tension, but few studies have been conducted on this. Three low‐aspect‐ratio reinforced concrete (RC) wall specimens subjected to coupled variable axial tension‐compression and lateral load were tested in this study, to investigate the effect of the fluctuating range of axial force and loading histories on the shear behavior of RC walls. The test results indicated that shear‐compression failure occurred under the compressive‐shear loading for all test wall specimens, and no obvious post‐peak strength degradation in tension‐shear loading. The hysteretic curves of test wall specimens were strongly affected by the loading histories; the shear strength and deformation capacity were mainly affected by the fluctuation of axial forces, especially for tension‐shear strength. The equation of ACI 318‐19 and JGJ 3‐2010 conservatively predicted the shear strength of RC walls under the variable axial force, while the equation of ASCE/SEI 43‐05 accurately predicted the shear strength with the mean values of the VTest/VASCE of 0.97 and 0.94 for compression‐shear and tension‐shear strength, respectively. Comparison with an RC wall under constant axial tension revealed that the failure modes of RC walls were strongly dependent on the initial cracking patterns. Finally, a finite element (FE) model was developed, and parametric analyses were carried out to further estimate the effect of variable axial force on the cyclic shear behavior of RC walls.

Mechanism of initiation and propagation of surface cracks in gun bore under thermomechanical coupling impact

Surface cracks in gun bore may exacerbate rifling ablation and wear and in turn shorten barrel life. Thermomechanical coupling finite element (FE) models of bore are established and the dynamic responses of the bore under high-temperature and high-pressure are numerically simulated. The stress distribution characteristics on the inner surface are analyzed and the effects of autofrettage, number of firings and harden layer on the stress distribution are discussed. Based on the stress distribution characteristics, FE models with two initial cracks on the ledge of land surface are set up and the propagation, interaction and intersection of the cracks are numerically simulated, considering the effect of the distance between the two cracks. Based on simulation results, the initiation and propagation pattern and mechanism of the cracks on the inner surface are analyzed. An ablation test system was designed and produced, and used to experimentally verify the initiation and propagation mechanism of the cracks. The observed crack patterns on the inner surface of a real gun bore are also used to illustrate the mechanism obtained in this work. Understanding of the initiation and propagation mechanism of cracks in gun bore can be applied to improve and optimize the design of barrels.

Multiscale modelling strategy for predicting fatigue performance of welded joints

This study predicts the fatigue performance of welded joints through a multiscale modelling strategy accounting for material and structural inhomogeneities. An S-N curve and detailed fracture surfaces with distinct beach marks were first derived by uniaxial fatigue tests utilising the designed cruciform welded joints. Considering the intrinsic features of welded joints, a multiscale modelling strategy was proposed to integrate multiple factors, including microstructural variations, strength distributions within the heat-affected zone (HAZ), and the diversity of three-dimensional weld toe shapes. Significantly, a modelling strategy was presented for the first time to simulate the simultaneous initiation, growth, and coalescence of multiple cracks, and was validated against experimental evidence. The results indicate that the proposed strategy can accurately predict both the fatigue strength and the overall crack growth process. Additionally, comparative assessments of single-crack and multiple-crack modelling strategies revealed notably shorter predicted fatigue lives when considering crack coalescence. Overall, this work establishes a multiscale framework for assessing the fatigue performance of welded joints considering both microscopic and macroscopic factors, offering substantial practical implications for engineering applications.

Toughening of a vacuum diffusion-bonded heterostructured AZ31/WE94/AZ31 alloy by interfacial reinforcement

Heterostructured materials have recently attracted extensive attentions from the materials community due to their superior combination of strength and ductility as compared to the conventional homogeneous counterparts. In the present study, the laminate AZ31/WE94/AZ31 Mg alloy was produced by vacuum diffusion bonding. The post annealing was carried out to improve the mechanical properties of the heterostructured Mg alloy. It is found the elemental diffusion and formation of interfacial phases enhance the interface bonding strength, thereby improving the comprehensive mechanical properties. The laminate sample annealed at 470 °C for 12 h shows a superior mechanical properties with a yield strength, ultimate tensile strength, and elongation of 158 MPa, 212 MPa and 12.9%, respectively. The higher annealing temperature leads to the growth of interfacial phase, which provides preferential nucleation sites for crack initiation and weakens the tensile properties.

Mechanical characteristics of kenaf-glass fiber reinforced hybrid composites by varying the stacking sequences

Fiber composite materials are preferred for their lightweight, low-cost, and commercial uses. As part of this study, laminate materials consisting of two different fiber materials as their reinforcement materials are produced using the hand layup method. This study investigates the mechanical properties of hybrid composite laminates fabricated using kenaf and glass fibers. Six stacking arrangements of the fibers are examined, alongside two reference laminates with individual reinforcements. Epoxy resins HY951 and LY556 serve as matrix materials. ASTM standards guide the mechanical testing of the composites. Results indicate varied tensile strengths based on stacking sequence, with laminate L2 (KKGKK) featuring a single glass fiber core at 75 MPa, and increasing strengths in laminates with additional glass layers: L1 (GKKKG) at 123 MPa, L5 (KGKGK) at 110 MPa, L3 (GKGKG) at 150 MPa, L6 (KGGGK) at 118 MPa, and L4 (GGKGG) at 159 MPa, the highest among all. It was observed that adding one layer of glass fiber with kenaf fiber boosts strength and modulus by 9.52% and 12.19% respectively, compared to pure kenaf fiber composites. Morphological analysis via Scanning Electron Microscopy (SEM) confirms failure due to initial crack propagation in the matrix and fibers. This study offers insights into hybrid composite laminate behavior, pertinent for various industrial applications.

Characterizing the Self‐Healing Asphalt Materials: A Neutron Imaging Study

Given the significant role of asphaltic pavement in surface transportation systems, even minor enhancements in asphalt materials hold the potential for cost savings and reduced environmental impacts. The healing properties of asphalt have drawn interest for sustainability, yet much remains unknown about the causes and influencing factors. To leverage self‐healing for extending pavement life, understanding the mechanisms and conditions that stimulate microcrack healing is essential. This study aims to investigate the dynamic progress of microcrack closure in asphalt mastics. The time‐series evolution of crack closure led by self‐healing is tracked by neutron computed tomography, with image processing facilitating volumetric analysis over a 7 h period. The study examines the healing process in mastic samples with three different sand filler contents (10, 20, and 30%). Results show that for all the investigated samples, the healing rate declines exponentially over time, with 100% recovery not achieved after 7 h at room temperature. Filler content‐influenced healing speed and 20% sand demonstrate the best performance. Meanwhile, the healing performance varies within the 10% and 30% groups, depending on initial crack size. Additionally, the study finds that initial crack size influences healing behavior in the samples.

Crack failure behaviors of Ti–6Al–4V dovetail joints subjected to fretting fatigue and effect of laser shock dimple-textured surface coated with diamond-like carbon film

Fretting damage can lead to a reduction in fatigue strength by more than half, due to the increased stress on the fretting surface, which accelerates crack initiation and propagation. Laser shock peening (LSP) technology is an advanced method for protecting against fretting fatigue, which reduces the effective stress on the fretting surface of components by introducing a deeper compressive residual stress field. In this work, LSP was utilized to create regularly arranged dimples on the surface of titanium alloy dovetail joints, and followed by diamond-like carbon (DLC) coating to alter fretting friction. Five surface treatment samples including as-machined, conv-LSP, LSP dimple-textured, DLC, LSP dimple-textured + DLC, were prepared for fretting fatigue tests on dovetail joints. The experimental results showed that the fatigue performance of specimens treated with LSP dimple-textured + DLC is better. Furthermore, it is found that wear debris from fretting surface was discharged into crack source area during fretting fatigue, leading to the formation of a fracture debris area forms in the crack initiation zone. The crack initiation zone displays the protrusion morphology characteristics due to the friction effect induced by contact loads. There is an internal correlation between the size of fracture debris area and surface wear resistance. Fracture debris area and the protrusion morphology vary with surface treatments and applied load. This research further reveals that the variation characteristics of the crack initiation area including the fracture debris area, have a positive influence on observing and analyzing failure behavior of fretting fatigue damage.

Rolling contact fatigue property of gradient rare earth addition M50 bearing steel with surface nano-grains and its inhibited martensite decay

A gradient nanostructured surface layer of ∼600 μm in thickness was prepared on M50 steel with rare earth additions by a surface mechanical rolling treatment. The initial microstructure was refined into nanosized grains (∼29 nm in diameter) in the top surface layer, causing a significant increase of surface hardness. Meanwhile, the grain size increases, and the microhardness decreases gradually to the matrix values with increasing depth. Rolling contact fatigue tests showed that the fatigue lives are significantly increased by the gradient nanostructured surface layer. Analysis of failure mechanism revealed that both softening in the near surface layer and hardening in the subsurface occur under rolling contact testing. And surface spalling is the predominant failure mode, of which the cracks initiate from primary carbides in the top surface layer owing to surface softening. In gradient nanostructured samples, the nano-grains inhibit carbon migration by impeding dislocation movement in the near surface layer, so that martensite decay is suppressed. Consequently, the crack initiation is inhibited, and the fatigue property is enhanced.