Crack Propagation Research Articles

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.

Evaluation of polyester high-tenacity fabric and carbon nanotube reinforcements for improving flexural response in concrete beams.

This research scrutinized the effectiveness of utilizing polyester high tenacity fabrics to enhance the functionality of concrete panels. Two distinct woven fabrics with comparable strength resistance were fabricated and assessed. Concrete beams were compared in their original form and those reinforced with woven fabrics, along with beams reinforced with carbon nanotubes (CNTs) (B, BC2, BC4, BS1, and BS2). Results indicated that the textile-reinforced concrete panels displayed notably greater energy absorption capabilities post-failure under flexural loads in comparison to the control and CNT-reinforced panels. This enhanced performance was credited to the development of multiple cracking patterns in the textile-reinforced panels. The flexural behavior of the textile-reinforced panels was characterized by four discernible phases: a linearly increasing segment, a crack propagation phase featuring multiple cracking, a post-cracking phase with reduced stiffness, and ultimately, failure due to fabric rupture or debonding. Conversely, the control and CNT-reinforced panels exhibited a more brittle response post-initial cracking, with a limited number of cracks and reduced deformation capacity. The performance of the textile samples was largely unaffected by their specific characteristics, except for the fabric wrapping angle. The introduction of 0.04% CNTs marginally enhanced crack flexural resistance compared to the control and 0.02% CNT panels, owing to the varied distribution of CNTs within the matrix. Overall, the textile-reinforced concrete panels demonstrated superior load-bearing capacity, ductility, and energy absorption when compared to the other reinforcement techniques examined.

Crack Development and Electrical Degradation in Chromium Thin Films Under Tensile Stress on PET Substrates

The mechanical and electrical deterioration of chromium (Cr) thin films sputtered onto polyethylene terephthalate (PET) substrates under tensile strain was studied. Understanding mechanical and electrical stability due to imposed strain is particularly important for device reliability, as the demand for flexible electronic devices increases. Cr thin films, widely spread across the field of electronic and sensor applications, face crack propagation with electrical degradation with tensile stress that can seriously compromise the performance. Accordingly, this study offers new findings on how Cr film thickness might influence crack formation and electrical resistance differently and also the general guidelines for flexible electronic component design with respect to long-term durability. Electrical resistances were measured while mechanically stretching 100- and 200 nm thin sheets. The study focused on crack development and propagation mechanisms in both film thicknesses and their effects on percentage change in electrical resistance (PCER). Scanning electronic microscopy (SEM) was used to characterize surface morphology and observe cracks as the strain rose. Early crack formation in 100 nm Cr films led to rapid PCER increases due to quick crack propagation and fast electrical degradation. Thicker 200 nm films, however, showed a more gradual PCER rise with fewer but deeper cracks, indicating a regulated strain response. Unlike the sharp PCER spike in 100 nm films, 200 nm samples were more variable, with three out of four showing a slight PCER decrease at the end, hinting at partial crack repair or conductive realignment before full failure. These results underscore the role of layer thickness in managing crack propagation and electrical stability, relevant for flexible electronics and strain sensors. This paper is aligned with the ninth goal of the United Nations Sustainable Development Goals, specifically Target 9.5: Enhance Research and Upgrade Industrial Technologies.

Simulation and Experimental Analysis of Surface Crack Propagation in Oscillating Bearings

: This study investigates the propagation of surface cracks in bearings under oscillating conditions. Voronoi elements are employed to simulate the microstructure of bearings, and combined with a cohesive zone model of continuum damage mechanics to simulate the propagation of cracks. A new type of oscillating contact fatigue test machine was designed to conduct experiments on contact crack propagation under oscillating conditions, and the experimental results were analyzed. By comparing the simulation results with experimental data, the validity of the theoretical analysis was confirmed.

Effect of grain size and grain boundary type on intergranular stress corrosion cracking of austenitic stainless steel: A phase-field study

A phase-field model coupled with polycrystalline microstructure is utilized to investigate the effect of grain size and grain boundary types on intergranular stress corrosion cracking in austenitic stainless steels. Considering the dilute solution environment, the free energy density of the two phases is hypothesized to be in parabolic form. The slower corrosion crack propagation rate in coarse-grained microstructures can be attributed to a higher frequency of transgranular cracking. Low-angle grain boundaries can effectively deflect intergranular corrosion cracks into grains with lower corrosion susceptibility, thereby impeding crack propagation. Twin boundaries mitigate corrosion crack propagation by reducing potential initiation sites.

Comprehensive Analysis of Major Fault-to-Failure Mechanisms in Harmonic Drives

The present paper proposes a detailed Failure Mode, Effects, and Criticality Analysis (FMECA) on harmonic drives, focusing on their integration within the UR5 cobot. While harmonic drives are crucial for precision and efficiency in robotic manipulators, they are also prone to several failure modes that may affect the overall reliability of a system. This work provides a comprehensive analysis intended as a benchmark for advancements in predictive maintenance and condition-based monitoring. The results not only offer insights into improving the operational lifespan of harmonic drives, but also provide guidance for engineers working with similar systems across various robotic platforms. Robotic systems have advanced significantly; however, maintaining their reliability is essential, especially in industrial applications where even minor faults can lead to costly downtimes. This article examines the impact of harmonic drive degradation on industrial robots, with a focus on collaborative robotic arms. Condition-Based Maintenance (CBM) and Prognostics and Health Management (PHM) approaches are discussed, highlighting how digital twins and data-driven models can enhance fault detection. A case study using the UR5 collaborative robot illustrates the importance of fault diagnosis in harmonic drives. The analysis of fault-to-failure mechanisms, including wear, pitting, and crack propagation, shows how early detection strategies, such as vibration analysis and proactive maintenance approaches, can improve system reliability. The findings offer insights into failure mode identification, criticality analysis, and recommendations for improving fault tolerance in robotic systems.

Influence of Cooling Rate on Primary Silicon Size in Hypereutectic Al–Si Alloy Fabricated by Laser Powder Bed Fusion

Herein, the effects of cooling rate on primary silicon (Si) phases in laser powder bed fusion (PBF‐LB/M) processed hypereutectic Al–Si alloy are investigated. These alloys are particularly in demand for automotive and electronic applications, thanks to their excellent wear and thermal properties. Nevertheless, when processed by conventional methods like casting with comparatively lower cooling rates, the coarse primary Si phases are responsible for increasing brittleness and inducing crack propagation. The refinement of the primary silicon phases is aimed to be achieved through the PBF‐LB/M process, which offers a high cooling rate. The primary Si phases are observed under three different thermal substrate plate conditions—untempered, with cooling and heating, and additionally with varying volume energy density. Furthermore, the impact of primary Si size on the hardness of the fabricated samples is evaluated. The findings show that a faster cooling rate has a notable effect on refining the primary Si size. Then, hardness is directly affected by the primary Si size, with larger Si resulting in decreased hardness.

Exploring the mechanical and biological properties of a resin-ceramic composite with biomimetic nacre structure containing zinc used for prosthodontics

Enhancement of the mechanical and biological properties of dental restoration materials is of significant importance. Drawing inspiration from the architecture and mechanical properties of natural nacre, we employed a low-cost accumulative rolling process to develop resin-ceramic composites with suitable hardness and high toughness. Plate-like aluminum oxide powder with diameters of 5–10 μm and nano-zinc oxide (ZnO) with antibacterial properties were mixed as the ceramic phase of the composite. Aluminum oxide ceramic plates were stacked using an accumulative rolling process to achieve a consistent orientation, followed by sintering to obtain porous ceramic scaffolds. The ceramic scaffolds were subsequently immersed in methyl methacrylate resin to complete the fabrication of the biomimetic composites. The mechanical and biological properties of the composites were comprehensively tested. The composites had a suitable hardness (1.09–1.63 GPa), excellent flexural strength (156.7–167.8 MPa), and fracture toughness (KIC = 2.66–3.59 MPa m1/2). Biomimetic composites are expected to mitigate the wear of natural teeth without developing fractures or deformations, while also exhibiting excellent cytocompatibility and antibacterial activity. This study investigated the factors influencing crack propagation in fracture tests and provided insights into enhancing the toughness of dental restorative materials. The biomimetic resin-ceramic composites containing Zn developed in this study have the potential to be used as functional dental restoration 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.

Robotic destructive and nondestructive testing of concrete structures

Structural elements may develop defects due to severe environmental conditions. Nondestructive testing is a common method for structural evaluations; however, these structures may be inaccessible or located in unsafe areas. In this paper, a Sawyer robot was employed to carry nondestructive testing (NDT) sensors such as Ground Penetration Radar (GPR) and Impact Echo (IE). The experiment comprised twelve reinforced concrete beams divided into four groups: Control (without defects), Void, Corrosion, and Debonding. The beams underwent three-point bending tests, with loads distributed across three levels: 50 %, 75 %, and 100 % of the failure load. Robotic and handheld IE and GPR tests were conducted, with IE performed before the actual test and GPR conducted before, during, and after the tests. Load-displacement diagrams were subsequently generated. The comparison between robotic and handheld tests demonstrated the high accuracy of the robotic NDT and indicated that the defects led to reduced load capacity and increased crack propagation.

Study on micro-grinding mechanism and surface quality of hardened 20 vol% SiCp/Al composites

Particle-reinforced aluminum-based silicon carbide composites (SiCp/Al) are widely used in aerospace, rail transit, and other fields due to their excellent comprehensive properties. However, the incorporation of high-brittle SiC particles poses challenges in the high-performance processing of SiCp/Al composites. This study focuses on hardened 20 vol% SiCp/Al composites, establishing two-dimensional finite element cutting models for single SiC particles. Micro-grinding experiments are conducted under various processing parameters. The influence law of surface defects on individual SiC particles relative to tool position and single factor machining parameters was analyzed, revealing the micro-grinding mechanisms affecting surface and subsurface quality. The results show that the interaction among particle damage mechanisms, crack propagation directions, and the restraining effects of the Al matrix leads to diverse types of defects at different cutting positions. Both simulation and experimental observations reveal surface defects such as pits, gullies, and burrs, while subsurface damage primarily results from crack invasion, cavity interstices, and pits due to particle breakage. The experiment achieved a minimum roughness of 0.057 μm. Taking into account the thermal softening of the material and the micro-behavior of the tool-chip interface, optimal conditions for improved surface quality involve a grinding depth of 0.03 mm, a spindle speed of 12,000 rpm, and a relatively low feed rate.

Effect of Rolling Process Parameters on Transverse Cracks on the Surface of Q345 Steel

This article examines the evolutionary behavior of transverse surface cracks in Q345 steel during the hot‐rolling process under various rolling conditions. “V”‐shaped cracks are prefabricated on the billet surface for laboratory hot‐rolling tests, and a corresponding rolling model is developed to validate its accuracy. The slab rolling model is established based on actual onsite rolling process parameters. The aim is to analyze the effects of different rolling conditions on the surface crack morphology and aspect ratio. The results indicate that variations in roll diameter (1400, 1300, and 1200 mm) influence crack propagation, with cracks unfolding earlier when the roll diameter is 1400 mm. At varying initial rolling temperatures (1300, 1200, and 1100 °C), cracks begin to unfold earlier at the highest temperature of 1300 °C. When examining different friction coefficients (0.4, 0.5, and 0.6), cracks unfold earlier at the highest coefficient of 0.6. Similarly, at different rolling speeds (3, 4, and 5 m s−1), cracks unfolded earlier at the highest speed of 5 m s−1. Analysis of changes in crack depth and aspect ratio during rolling shows that the initial few passes have a greater influence on crack depth and unfolding. In the later stages of rolling, cracks continue to unfold, though the depth shows minimal variation, and the aspect ratio tends to approach zero.

Relation Between Striations Spacing and Fatigue Crack Growth Rates for Additive Manufactured Inconel 625

ABSTRACTThe principles of the mechanisms for fatigue crack propagation in metals have been established several decades ago. By definition, fatigue might be summarized as a damage process imparted to a material under the action of cyclic loads. The relation between fatigue crack growth rates (FCGRs) and formation of striation marks has been a controversial topic. Some authors stated that, in certain fatigue regimes, several fatigue cycles are required to form a single striation. The disagreement found was the motivation for the present work. This study's main goal is to provide a comparison between the striation spacing and the respective FCGR. These analyses will be performed in a Nickel superalloy, Inconel 625, obtained via directed energy deposition. Investigation of the striations spacing are compared with data obtained from FCGR tests. A good agreement between striation spacing and FCGRs was found to intermediate and large values of stress intensity factor.

The tensile behaviors of Ag-Cu alloys with different Cu contents: Molecular dynamics simulations study

The Ag-Cu alloys have received attention due to their excellent electrical and mechanical properties. However, the analytical research on why the mechanical properties of the Ag-Cu alloys increase after a small amount of Cu atoms are added is still lacked. In this work, the classical molecular dynamics (MD) simulations method was used to establish the Ag-Cu alloy models with different Cu contents. The tensile deformation mechanism of Ag-Cu alloy at room temperature was revealed from the atomic scale through the analysis of the stress-strain behavior and the evolution of dislocations. During the simulations, the embedded atom method (EAM) potential was used to describe the interaction between Ag atom and Cu atom. The uniaxial tensile deformation and nanostructure evolution of Ag-3 at.% Cu, Ag-6 at.% Cu and Ag-10 at.% Cu alloy models at the temperature of 300 K and the strain rate of 0.02 Å/ps were studied in detail. Results show that the internal stress was generated due to the large lattice mismatch among Ag atom, Cu cluster and the grain boundary. It results in the formation of dislocation and the negative initial stress at the beginning stage of Ag-Cu alloy models under tension. The dislocation firstly nucleates at the grain boundary and the growth rate of dislocation is slow before the crack propagation, and the complex dislocation reactions also exist. With the increase of Cu content, the tensile strengths of Ag-Cu alloys also increase. Cracks mainly form at the intersection of multiple grains, and the fracture mode changes from the intergranular fracture to the intergranular fracture and transgranular fracture after the unstable propagation of cracks. Meanwhile, a plenty of Cu atoms are distributed in the form of clusters in Ag matrix. They hinder the slip of dislocation and slow the relative sliding between atomic layers, and thus finally improves the deformation resistance to the plastic deformation of Ag-Cu alloy. The study on the tensile deformation behavior of Ag-Cu alloy at room temperature has certain guiding significance for the practical production and application of the design of Ag-Cu alloy.

Initial temperature conduction process and fracture response of rock impacted by ultra-low-temperature fluid: A case study of polymethyl methacrylate

Injecting ultra-low-temperature fluids, such as liquid carbon dioxide (CO2) and liquid nitrogen (LN2), into deep, low-permeability reservoirs for fracturing is an emerging waterless fracturing technology. When these fluids enter the reservoir, they rapidly exchange heat with the fracture walls, triggering intense cold shock, which influences fracture development. Although many scholars have studied the effects of nitrogen freezing and thawing on coal seams, the initial thermal exchange and cold shock process when LN2 first enters the rock mass remains unclear. This paper uses the visualizable material polymethyl methacrylate (PMMA) as the research object, conducting low-temperature impact experiments under different preset temperatures (20 °C, 40 °C, 60 °C, and 80 °C) to investigate the impact of thermal exchange during cold shock on PMMA fracturing. The results show: (1) During LN2 impact, PMMA's temperature changes in three stages: slow cooling (micro-cracks initiation), rapid cooling (formation of long fractures), and temperature recovery (crack formation completion). (2) In prolonged impacts, PMMA temperature decreases linearly, while in short-term cyclic impacts, temperature decreases exponentially with faster recovery, increasing the likelihood of micro-cracks formation. (3) Temperature differences have a dual effect on crack formation and propagation: they significantly enhance internal thermal stress, leading to rapid micro-cracks initiation and expansion, while also causing uneven temperature gradients in the crack propagation region, shifting fracture modes from tensile to complex composite failures and promoting secondary crack formation. However, a significant temperature differential may result in the development of a singular crack propagation path, hindering the formation of complex fracture networks. These findings offer theoretical insights into fracture network formation in waterless fracturing of low-permeability reservoirs.

Acoustic emission and 4D X-ray micro-tomography for monitoring crack propagation in rocks

Acoustic emission (AE) and 4D X-ray computed tomography (4D XCT) were used simultaneously to study crack initiation and propagation in two different types of quartz-rich sandstones during the four-point bending experiments. Statistical analysis of the AE response indicated the failure mechanisms and their dynamics. The characteristic changes observed in the AE response defined the timing of the bending interruptions for XCT scanning to reveal the development of the crack. It was possible to quantitatively describe the developing cracks in their dimensions and volume and relate this information to the rate of decrease in the post-peak region of the material response. It could be concluded that the combination and concurrent use of AE and XCT techniques represents a highly effective and reliable instrument for observation, description, analysis of the crack propagation process, and rock disintegration in detail at a microscale level. With regard to the specific sandstones studied, Mšené sandstone is softer, respectively, less brittle, while Kocbeře sandstone is characterised by a more brittle behaviour accompanied by an AE signal with higher amplitudes compared to those of Mšené.

Dynamic tensile behaviors and crack propagation in fiber-reinforced cementitious composites: Experimental investigation and Peridynamic simulation

Fiber-Reinforced Cementitious Composites (FRCC) have gained significant attention in engineering applications due to their superior mechanical properties and toughness, particularly under high strain rate conditions. This study performed dynamic tensile tests on FRCC at high strain rates (35-110 s⁻¹) using a Split Hopkinson Tensile Bar (SHTB) apparatus. Additionally, a novel Peridynamic (PD) model was developed for the SHTB and FRCC system, leveraging the advanced capabilities of the emerging PD theory. The study compared and analyzed dynamic tensile strength, ultimate tensile strain, strain rate effects, failure modes, and crack development in FRCC with different fiber ratios at various high strain rates, using both experimental data and PD simulations. The results show that the PD-SHTB-FRCC dynamic model developed in this study exhibits high consistency between numerical simulations and experimental findings, effectively capturing the processes of crack initiation, propagation, and complete failure in FRCC specimens. The dynamic tensile properties of FRCC improve significantly with increased strain rates, with polyethylene (PE) fibers providing superior reinforcement compared to steel fibers. Notably, the dynamic tensile strength, peak tensile stress, and ultimate tensile strain of FRCC increase significantly with rising strain rates, with specimens containing higher PE fiber content showing a more pronounced enhancement effect. For strain rates between 42.6 s⁻¹ and 76.1 s⁻¹, considering dynamic tensile strength, ultimate tensile strain, and peak tensile stress, the optimal combination for resisting dynamic tensile loads was 1.5% PE fibers and 0.5% steel fibers. At a strain rate of 99.8 s⁻¹, a 2% PE fiber ratio alone provided the best performance.

Effective stress intensity factor range for fatigue cracks propagating in mixed mode I-II loading

The actual service axles are often subjected to mixed-mode loading, and predicting the mixed-mode I-II crack propagation behaviour using the mode I effective stress intensity factor (ΔKI) differs from the real service conditions. To effectively predict the fatigue crack propagation behaviour of actual service structures, the I-II stress intensity factor range (ΔKP-R) considering two closure effects was adopted to describe the fatigue crack propagation under mixed mode loading. A test database was established based on monitoring data of mode I and mixed-mode I-II (30/45/60°) crack propagation tests under different stress ratios. Combining domain knowledge and symbolic regression (SR) methods, an angle factor was proposed for constructing correlation functions between ΔKI and ΔKP-R. The results showed that the loading angle (α) only affects the initial projection of the load parallel and perpendicular to the fatigue crack growth (FCG) direction. Compared with the geometric correction factor, the correlation function acquired by the angle factor constructed by the SR method has higher accuracy, and the balance parameters (SCORE) obtained by the former are significantly higher than those obtained by the latter under the same function complexity. The SR verification results demonstrated that constructing mode I and I-II correlation functions with angle factors has a good predictive effect.

Effects of defects on the high-temperature performance of selective laser melting K418 superalloys: An in-situ 3D X-ray analysis

Defects are inevitable in selective laser melting process, significantly impacting the mechanical properties of materials and reducing their service life. In this study, the effects of various defects and their distribution on the high-temperature mechanical performance of the selective laser melted K418 superalloys were investigated via an in-situ 3D X-ray analysis and finite element method. The results showed that the selective laser melting process can significantly enhance the strength of the K418 sample, while degrading the fracture elongation. The sphericity and location of defects are the two key parameters influencing the mechanical performance. The defects with low sphericity at the sub-surface resulted in elevated local stress and strain, accounting for the significant degradation in fracture elongation. Locally increased stress and accumulated strain around lack of fusion defects at the sub-surface contribute to the initiation and propagation of crack. This study provides inspiration for understanding the correlation between the defects and mechanical properties.

New route for fabricating low-carbon ductile martensite to optimize the stretch-flangeability of dual-phase steel

Traditional cold-rolling dual-phase steel (CR sheet), limited by poor stretch-flangeability as indicated by the hole expansion rate (HER), faces challenges in manufacturing complex automobile parts. To address this, a new type of hot-rolling dual-phase steel with an 800 MPa grade (manufactured by tyipical thin slab continuous casting and rolling process, TSCCR) was designed to replace the traditional one. The TSCCR sheet, with a lower carbon content of 0.047wt.%, compared to 0.093wt.% in the CR sheets, features 40.6% martensite significantly higher than 28.2% in the CR sheet. This increased martensite content, despite being softer and more ductile due to its low hardness, compensates for the tensile strength in the TSCCR sheet. Furthermore, the TSCCR sheet exhibits a unique heterostructure characterized by uneven carbon distribution from the ferrite/austenite interface to other boundaries/interfaces, estimated by the negligible partition local equilibrium (NPLE) model of ferrite transformation. This unique heterostructure diminishes the mechanical disparity between ferrite and martensite, resulting in a higher yield strength of 568 MPa, compared to 456 MPa in the CR sheet. During uniaxial tension, the ferrite and ductile martensite in the TSCCR sheet initiate cooperative plastic deformation earlier than in the CR sheet, despite initially having fewer favorable slip systems in the TSCCR martensite. The low working hardening rate of the TSCCR sheet facilitates the forming layered structure of ferrite and martensite during necking compared to the CR sheet. Consequently, the HER of the TSCCR sheet sharply increased by 144% compared to the CR sheet. This enhancement in HER can be attributed to the crack initiation area, longer crack propagation path, and higher crack propagation resistance facilitated by the ductile martensite, culminating in superior HER.