3D Crack Research Articles

Regularized X‐FEM Modeling of Arbitrary 3D Interacting Crack Networks

ABSTRACTAn extension to the Regularized eXtended Finite Element Method (RX‐FEM) is proposed that allows arbitrary 3D cracks through a novel hierarchical enrichment algorithm. The technique avoids geometric consideration of how a crack cuts elements or intersects other cracks. Each crack is described separately in terms of its sign distance function and regularized step function, which are only recorded for nodes in the region where the gradient of the regularized step function is non‐zero. The algorithm creates a set of superimposed nodes, referred to as node twins, and elements, referred to as twinned elements, for each crack and determines the connectivity of the element twins using the involved crack indices. The displacement jump is calculated between each pair of element twins corresponding to the same crack, and a cohesive zone model (CZM) is formulated for each pair of twins to model crack opening. Following the theory for the novel method, several examples are presented that illustrate capabilities of the new method that the traditional RX‐FEM formulation lacked. A quasi‐2D example of offset crack propagation is considered and successfully compared with published results. Additionally, two 3D examples involving perpendicularly intersecting cracks are considered, illustrating the intersection of two crack fronts and correct partitioning of the domain into eight fragments due to three crossing cracks, respectively.

Analysis of crack propagation due to fatigue using the Stable Generalized Finite Element Method (SGFEM)

This work aims to present a combination of the stable generalized finite element method (SGFEM) and of the displacement correlation method (DCM) for analyzing 2D crack propagation problems due to fatigue. The SGFEM allows to model fracture mechanics problems without excessive refinement and/or concern of the mesh-to-crack alignment. Additionally, this method maintains the numerical conditioning under control. The DCM, in turn, is computationally very efficient when compared to traditional energy based methods (like J integral) and herein is even improved by means of a linear least square extrapolation. The maximum circumferential tension criterion and well-known propagation laws available in literature are adopted for considering the crack propagation. Experimental and numerical benchmark examples are proposed and the obtained results are compared against results provided by a commercial software widely adopted in the aeronautics industry.

Numerical prediction and experiments for 3D crack propagation in brittle materials based on 3D-generalized maximum tangential strain criterion

Accurately predicting and tracing the three-dimensional (3D) propagation and fracture trajectory of a crack inside brittle materials is challenging. One difficulty is that the 3D crack propagation exhibits complex I/II/III mixed-mode expansion, and there is a lack of accurate crack initiation criteria and effective simulation methods. In our previous studies, the 3D-generalized maximum tangential strain (3D-GMTSN) criterion was proposed to determine the direction and onset of 3D fracture initiation. In this study, a Python program based on the 3D-GMTSN criterion is developed and integrated into FRANC3D to predict the 3D propagation trajectory of an arbitrary crack inside brittle solids. To verify the reliability of the new method, three different types of 3D crack modes, namely Internal Inclined Cracks Cuboid (IICC), Edge Notched Disc Bend (ENDB), and Three-Point Bending (TPB), are used for fracture experiments. The 3D crack propagation morphology is identified using high-resolution CT imaging techniques. The IICC, ENDB, and TPB models are simulated using the new method and the conventional numerical method based on the maximum shear stress (MSS), maximumtensile stress (MTS), and maximum energy release rate (MERR) criteria. Comparisons indicate that the proposed method based on the 3D-GMTSN criterion can predict the 3D crack propagation trajectory more accurately than the conventional methods.

Poromechanical cohesive interface element with combined Mode I-II cohesive zone elastoplasticity for simulating fracture in fluid-saturated porous media

A combined Mode I-II cohesive zone (CZ) elasto-plastic constitutive model, and a two-dimensional (2D) cohesive interface element (CIE) are formulated and implemented at small strain within an ABAQUS User Element (UEL) for simulating 2D crack nucleation and propagation in fluid-saturated porous media. The CZ model mitigates problems of convergence for the global Newton-Raphson solver within ABAQUS, which when combined with a viscous stabilization procedure allows for simulation of post-peak response under load control for coupled poromechanical finite element analysis, such as concrete gravity dam stability analysis. Verification examples are presented, along with a more complex ambient limestone-concrete wedge fracture experiment, water-pressurized concrete wedge experiment, and concrete gravity dam stability analyses. A calibration procedure for estimating the CZ parameters is demonstrated with the limestone-concrete wedge fracture process. For the water-pressurized concrete wedge fracture experiment it is shown that the inherent time-dependence of the poromechanical CIE analysis provides a good match with experimental force versus displacement results at various crack mouth opening rates, yet misses the pore water pressure evolution ahead of the crack tip propagation. This is likely a result of the concrete being partially-saturated in the experiment, whereas the finite element analysis assumes fully water saturated concrete. For the concrete gravity dam analysis, it is shown that base crack opening and associated water uplift pressure leads to a reduced Factor of Safety, which is confirmed by separate analytical calculations.

Study of three-dimensional crack extension in turbine discs of short-life turbojet engines

Abstract A simulation study on the 3D crack extension of short-lived turbojet engine turbine discs was carried out using FRANC3D 3D fracture mechanics software combined with ABAQUS finite element software. By establishing a 3D geometric model of the turbine disc, the crack extension process is simulated by using the sub-model method, and the crack extension behavior and failure mode are analyzed to predict the remaining life of the cracked wheel disc. The results show that the crack expansion path matches well with the crack failure phenomenon of the turbine disc under the actual working conditions; the turbine disc crack is dominated by Type I (open Type) crack expansion, and the stress intensity factors of Type II and Type III are negligible; the crack expansion rate increases slowly with the increase of crack depth, and it rises steeply at the critical value of the fracture failure; and the residual life of the turbine disc is 32 cycles. This study provides empirical analyses for crack monitoring and life prediction of turbine discs and is of great significance for engine maintenance and reduction of end-of-life costs of turbine components.

Visualization test and numerical simulations of 2D blasting crack propagation

Drilling and blasting, characterized by their efficiency, ubiquity, and cost-effectiveness, have emerged as predominant techniques in rock excavation; however, they are accompanied by enormous destructive power. Accurately controlling the blasting energy and achieving the directional fracture of a rock mass have become common problems in the field. A two-dimensional blasting (2D blasting) technique was proposed that utilizes the characteristic that the tensile strength of a rock mass is significantly lower than its compressive strength. After blasting, only a 2D crack surface is generated along the predetermined direction, eliminating the damage to the reserved rock mass caused by conventional blasting. However, the interior of a natural rock mass is a "black box”, and the process of crack propagation is difficult to capture, resulting in an unclear 2D blasting mechanism. To this end, a single-hole polymethyl methacrylate (PMMA) test piece was used to conduct a 2D blasting experiment with the help of a high-speed camera to capture the dynamic crack propagation process and the digital image correlation (DIC) method to analyze the evolution law of surface strain on the test piece. On this basis, a three-dimensional (3D) finite element model was established based on the progressive failure theory to simulate the stress, strain, damage, and displacement evolution process of the model under 2D blasting. The simulation results were consistent with the experimental results. The research results reveal the 2D blasting mechanism and provide theoretical support for the application of 2D blasting technology in the field of rock excavation.

Damage parameters and crack morphology in high strength concrete BBR9 under dynamic uniaxial compressive loading: An experimental study

In recent years, there has been significant growth in the use of high-strength concrete (HSC) in structures designed to withstand extreme events such as collisions, terrorist attacks, and earthquakes. Continuum damage mechanics has been utilized to develop constitutive models that can capture the damage evolution in concrete materials under such conditions. These models must be validated against experimental data obtained under controlled laboratory conditions. Yet, no experimental dataset currently exists that accurately quantifies the damage evolution and its influence on the residual mechanical properties of HSC. The present study aimed at investigating the damage initiation, progression, and morphology of HSC-Baseline Basic Research Mixture 9 (BBR9) when subjected to dynamic uniaxial compressive loading. A Kolsky compression bar system was implemented to introduce distinct damage states in the HSC-BBR9 specimens. Thereafter, the partially damaged specimens were tested to quantify their residual mechanical properties. Accordingly, stiffness-based and strength-based constitutive damage parameters were adopted to propose an indirect quantification of the damage state based on the deterioration of mechanical properties. In addition, the X-ray micro‐computed tomography (micro-CT) technique was utilized to extract measurements of 3D crack networks (e.g., crack volume and surface area) that provide a direct quantification of the damage state based on microstructural evidence. The results demonstrated that the HSC-BBR9 material can maintain its residual mechanical properties into the post-peak regime. In the initial stages of damage, stiffness and strength deteriorate at a proportional rate; however, as damage accumulates, the rate of stiffness degradation increases. Moreover, correlations between constitutive damage parameters and 3D crack measurements were established.

Analysis of tooth root three-dimensional fatigue crack initiation, propagation, and fatigue life for spur gear transmission

The gears in aviation gear systems are susceptible to fatigue fracture due to high-speed, heavy-load, and load alternation operating conditions. Therefore, a numerical calculation model with multiple mesh positions loading form has been proposed in this paper to analyze the fatigue crack initiation and propagation behavior, and to estimate the fatigue life of these gears. The fatigue life of the gear is determined by separately calculating the fatigue crack initiation life and the fatigue crack propagation life. The tooth root fatigue stress and the fatigue initiation life are calculated by the multi-axial fatigue life prediction method with the Smith-Watson-Topper criterion and the critical plane method. Afterwards, the tooth root stress–strain field is calculated in Finite element (FE) software and the stress intensity factors of the crack tip are calculated in three-dimensional (3D) crack analysis software. Then, the tooth root fatigue crack propagation trajectory and the fatigue crack propagation life are obtained separately. Finally, the influence mechanism of the loading conditions, the geometry parameters of gears, and the initial crack positions on the tooth root fatigue crack initiation life, propagation life, and fatigue crack propagation trajectory are analyzed, and a tooth fatigue test bench is built for verifying the crack propagation trajectory.

Self-adaptive 2D[sbnd]3D image fusion for automated pixel-level pavement crack detection

Current 2D and 3D image-based crack detection methods in transportation infrastructure often struggle with noise robustness and feature diversity. To overcome these challenges, the paper use CSF-CrackNet, a self-adaptive 2D3D image fusion model utilizes channel and spatial modules for automated pavement crack segmentation. CSF-CrackNet consists of four parts: feature enhanced and field sensing (FEFS) module, channel module, spatial module, and semantic segmentation module. A multi-feature image dataset was established using a vehicle-mounted 3D imaging system, including color images, depth images, and color-depth overlapped images. Results show that the mean intersection over union (mIOU) of most models under the CSF-CrackNet framework can be increased to above 80 %. Compared with original RGB and depth images, the average mIOU increases with image fusion by 10 % and 5 %, respectively. The ablation experiment and weight significance analysis further demonstrate that CSF-CrackNet can significantly improve semantic segmentation performance by balancing information between 2D and 3D images.

Quenched disorder and instability control dynamic fracture in three dimensions

Materials failure in 3D still poses basic challenges. We study 3D brittle crack dynamics using a phase-field approach, where Gaussian quenched disorder in the fracture energy is incorporated. Disorder is characterized by a correlation length R and strength σ. We find that the mean crack velocity v is bounded by a limiting velocity, which is smaller than the homogeneous material’s prediction and decreases with σ. It emerges from a dynamic renormalization of the fracture energy with increasing crack driving force G, resembling a critical point, due to an interplay between a 2D branching instability and disorder. At small G, the probability of localized branching on a scale R is super-exponentially small. With increasing G, this probability quickly increases, leading to misty fracture surfaces, yet the associated extra dissipation remains small. As G is further increased, branching-related lengthscales become dynamic and persistently increase, leading to hackle-like structures and a macroscopic contribution to the fracture surface. The latter dynamically renormalizes the actual fracture energy until, eventually, any increase in G is balanced by extra fracture surface, with no accompanying increase in v. Finally, branching width reaches the system’s thickness such that 2D symmetry is statistically restored. Our findings are consistent with a broad range of experimental observations.

Microscopic interface deterioration mechanism and damage behavior of high-toughness recycled aggregate concrete based on 4D in-situ CT experiments

High-toughness recycled aggregate concrete (HTRAC), as an innovative green building material, showcases outstanding performance and environmental attributes. To investigate its microscopic structural characteristics and the mechanisms of damage evolution under loading, a series of 4D in-situ X-ray computed tomography (CT) experiments were conducted under uniaxial compression conditions. During the experimental process, detailed scans were performed on six key loading points (0 %, 30 %, 60 %, and 100 % of the peak load, 70 % and 40 % of the post-peak load of the specimen). Advanced three-dimensional image processing techniques were utilized to conduct a comprehensive analysis of internal features within the specimen, including pores, steel fibers, and cracks. The evolution of damage in HTRAC was characterized by both qualitative 2D crack slice analysis and quantitative 3D reconstruction analysis of cracks. Changes in the average grayscale values of CT cross-sectional images were also examined. The deterioration mechanism of recycled aggregate concrete interface cracks was elucidated by the combination of CT images and modeled HTRAC. Furthermore, a statistics model illustrating the interaction mechanism between damage, cracks, and strain was proposed. This study provides technical and theoretical support for the further promotion and application of high-toughness recycled aggregate concrete.

3D analysis of crack propagation in nuclear graphite using DVC coupled with finite element analysis

The initiation and propagation of cracks within nuclear graphite components compromise the lifespan of advanced gas-cooled reactors and even lead to safety incidents. A thorough understanding of fracture properties in nuclear graphite is crucial for the effective management and design of graphite structural components. In this work, an in-situ test of a double cleavage drilled compression (DCDC) specimen was conducted using X-ray tomographic imaging to fully analyze the 3D crack propagation behavior in IG-11 nuclear graphite. “Subvolume Splitting” digital volume correlation (SS-DVC) was employed to accurately quantify the displacement fields surrounding the crack. The entire 3D crack propagation and crack surface around the crack front were precisely captured through 3D imaging processing of the gray level residual (GLR) field. Additionally, crack opening displacements (CODs) and stress intensity factors (SIFs) were determined using finite element (FE) analysis with extended finite element method (XFEM). Experimental results indicate that although mode I crack remains predominant throughout the whole process, complex crack propagation exists around the crack front. The utilization of irregular crack surfaces in FE analysis helps to obtain refined displacement fields and accurate SIFs of the crack front. This work provides comprehensive insights into crack propagation and reveals the influence of complex crack morphology on SIF calculations, facilitating accurate prediction of structural integrity and rational design of graphite components.

Crack propagation arrest by the Joule heating in micro/nano-sized structures

The Joule heating technique is utilized to arrest the crack propagation so to protect some important structures being further damaged. In this approach there are created compression stresses at the crack tip vicinity due to a specific temperature distribution induced by the electric current. The Joule heating is amulti-physical problem which is applied here to micro/nano-sized structures. The size-effects are considered for description of both the elastic and the thermal fields. The heat conduction can’t be well described by classical Fourier’s law in nano-sized structures. A novel gradient theory is developed in such structures adopting the size effect of heat conduction. Besides, the strain gradients and double stresses are introduced into the constitutive laws. Then, the governing equations are given by partial differential equations with order of derivatives being higher than in classical theory. The principle of virtual work is the base of weak formulation and derivation of the discretized finite element equations for ageneral 2d boundary value problem with cracks. The collocation mixed FEM with large strain gradients is developed for numerical solution, where the C0 continuous approximation is applied independently to displacements and strains and also to temperature and temperature gradients. Kinematic constraints between strains and displacements are satisfied by the collocation method at selected interior points. The collocation mixed FEM is applied to solve 2D crack problems with Joule heating.

Adaptive Mesh Strategy for Efficient Use of Interface Elements in a 3D Probabilistic Explicit Cracking Model for Concrete.

In this paper, the development of a 3D adaptive probabilistic explicit cracking model for concrete is reported. The contribution offered herein consists in a new adaptive mesh strategy designed to optimize the use of interface elements in probabilistic explicit cracking models. The proposed adaptive mesh procedure is markedly different from other strategies found in the literature, since it takes into account possible influences on the redistribution of stresses after cracking and can also be applied to purely deterministic cracking models. The process of obtaining the most appropriate adaptive mesh procedure involved the development and evaluation of three different adaptivity strategies. Two of these adaptivity strategies were shown to be inappropriate due to issues related to stress redistribution after cracking. The validation results demonstrate that the developed adaptive probabilistic model is capable of predicting the scale effect at a level similar to that experimentally observed, considering the tensile failure of plain concrete specimens. The results also show that different softening levels can be obtained. The proposed adaptive mesh strategy proved to be advantageous, being able to promote significant reductions in the simulation time in comparison with the classical strategy commonly used in probabilistic explicit cracking models.

3D internal crack propagation in brittle solids under non-uniform temperature field: Experimental and numerical simulation

In the field of engineering, elevated temperatures often induce thermal stress. Especially in brittle materials, the propagation of internal cracks under such thermal stress is frequently the primary cause of failure. We utilize the 3D internal laser-engraved crack technology to create internal cracks at various locations inside the half-Brazilian disk specimens. By precisely controlling the power of the heating device, we achieved temperature non-uniformity of the external heat source, resulting in uneven heating of the material’s surface. Simultaneously, by adjusting the geometry of the material and using semi-Brazilian disk specimens, we generated uneven temperature gradients and thermal capacities along different heat conduction paths. The internal cracks at different locations also affect the distribution of thermal stress in the material, further influencing the formation of the non-uniform temperature fields (NUTF). Through the above methods, we successfully conducted physical experiments on the 3D propagation of internal cracks in brittle materials under NUTF. Additionally, we utilized J-integral and the finite element method for thermal analysis to conduct thermo-mechanical coupled 3D numerical simulations. Furthermore, we employed a polarising microscope to analyze the microscopic morphology of 3D internal cracks. Finally, we revealed the mechanism of 3D internal crack propagation under NUTF. The results show that prefabricated internal cracks in group A produce “n-shaped” crack at a height of 15 mm and “u-shaped” cracks at heights of 25 mm and 35 mm. Meanwhile, in group B, the eccentric prefabricated internal cracks ultimately produce “s-shaped” cracks. Through analysis, it was determined that the differential formation occurred due to relative sliding between the upper and lower surfaces of the crack under longitudinal shear stress induced by NUTF. Group A cracks have smooth surfaces, which are mode I-II cracks. group B generated “lance-like” fractures with obvious “anti-binary tree”, which are mixed mode I-II-III cracks. These findings provide an experimental and theoretical basis for the study of 3D internal crack propagation modes under NUTF and deepen the understanding of fracture mechanics in brittle materials.

Statistical analysis of microstructurally small fatigue crack growth in three-dimensional polycrystals based on high-fidelity numerical simulations

Microstructurally small cracks (MSCs) are sensitive to their local microstructural neighborhoods, resulting in highly variable 3D crack propagation within individual samples and among a population of samples. Statistically quantifying this complex spatiotemporal variability requires collecting and analyzing a large number of 3D MSC growth observations, which remains challenging due to experimental constraints that limit the availability of 3D observations of MSCs in the existing literature. We address this gap by leveraging virtual observations of MSC growth using a state-of-the-art, high-fidelity simulation framework to provide a statistical perspective on 3D MSC growth behavior. The MSC growth simulations were performed in 40 unique but statistically similar polycrystalline microstructures, and the data extracted from the virtual observations were collectively analyzed to quantify variability in geometric, microstructural, and micromechanical aspects of MSCs. Variability in tortuosity, crack surface crystallography, and MSC growth parameters (local crack extension and kink angle) were quantified statistically. The results show that 3D MSC surfaces do not necessarily propagate along {111} crystallographic planes despite crack traces on radial planes being closely aligned with {111} slip plane traces. Also, the 3D MSC surfaces exhibit increasingly tortuous propagation and spatially varying local crack growth rates (with variability as high as 59% among the population). Moreover, a correlation study revealed some of the highly influential microstructural and micromechanical features controlling MSC growth parameters. The quantified variability holds direct implications for advanced materials prognosis in engineering applications, and the identified features from the correlation study can be leveraged to train machine learning models for rapidly predicting MSC growth behavior in the future.

An adaptive phase field approach to 3D internal crack growth in rocks

Modeling the 3D internal crack under compression entails complex fracture mechanics (mode I-II-III fracture), resulting in substantial computational costs and challenges in characterizing fracture morphology characterization for Phase Field Method (PFM) simulations. In the present paper, we developed a 3D adaptive crack propagation model integrated into the PFM to study the internal cracks in rocks. The proposed locally refined solution was implemented within the isogeometric analysis (IGA) framework, utilizing PHT-splines and employing the phase field variable as an error indicator to accurately capture non-smooth crack surfaces. The simulation begins with a coarser mesh, and the spatial discretization is adaptively refined in real-time as the computation progresses and the phase variable threshold is reached. By comparing our results with previous numerical tests, we validated the effectiveness of our model in simulating crack growth. Notably, a smaller length scale parameter led to a higher peak force in notched square plates under tension, and our adaptive PFM successfully reduced errors caused by length scale parameters. We further validated our model by comparing it with uniaxial compression experiments on 3D-printed resin samples with internal penny-shaped cracks, achieving good agreement with the experimental data. Using the 3D adaptive PFM, we predicted changes in crack morphology and fracturing mechanisms by varying the inclination angles of internal penny-shaped cracks. Our numerical results showed that as the inclination angle increased, wing cracks initiated closer to the end tips of the original crack, and their length decreased due to the wings wrapping effect. The corresponding fracturing mechanisms transition from mode I-III fracture (0°) to mode I-II-III fracture (30°, 45°, 60°), and eventually to mode I fracture (90°) as inclination angles increase. Comparing 2D and 3D models, we found that the growth of wing cracks in 3D was significantly influenced by the intermediate principal stress. We conclude that the extended 3D adaptive PFM-based model accurately predicted complex mechanical behavior and crack growth patterns in rock.

A higher-order asymptotic solution for 3D sharp V-notch front tip fields in creeping solids

As one of the most important topics studied in creep fracture mechanics, mechanics fields at 3D sharp V-notch front tip in creeping solids have drawn remarkable attention at present. In this paper, the higher-order asymptotic analysis is carried out for 3D sharp V-notch front tip fields in creeping solids subjected to mode Ⅰ loading, and a 3D higher-order term solution is theoretically proposed by introducing the out-of-plane stress factor Tz to establish the 3D nonlinear governing equations of front tip fields. The present higher-order asymptotic solution for 3D sharp V-notch can naturally be degenerated to that for 3D crack. It is found that the stress exponents and angular distribution functions of higher-order terms for 3D notch and crack are highly related to Tz. The proposed 3D higher-order term solution overall shows better agreement with the FEA results than the existing 3D leading-term solution and 2D higher-order term solutions available in the literature, especially for smaller notch angle and shorter ligament lengths. Based on the 3D higher-order asymptotic solution, a new fracture parameter A2T is given and combined with Tz to characterize 3D constraint effect. It is noted that the effects of A2T and Tz on 3D constraint are highly interlinked rather than simply separated into in-plane and out-of-plane parts. The present 3D higher-order asymptotic solution can promote the understanding and characterization of 3D constraint effect and is of great significance in the evaluation of 3D fracture behavior and structural failure assessment under creep conditions.

Enhanced 3D printing and crack control in melt-grown eutectic ceramic composites with high-entropy alloy doping

As a 3D printing method, laser powder bed fusion (LPBF) technology has been extensively proven to offer significant advantages in fabricating complex structured specimens, achieving ultra-fine microstructures, and enhancing performances. In the domain of manufacturing melt-grown oxide ceramics, it encounters substantial challenges in suppressing crack defects during the rapid solidification process. The strategic integration of high entropy alloys (HEA), leveraging the significant ductility and toughness into ceramic powders represents a major innovation in overcoming the obstacles. The ingenious doping of HEA particles preserves the eutectic microstructures of the Al2O3/GdAlO3(GAP)/ZrO2 ceramic composite. The high damage tolerance of the HEA alloy under high strain rates enables the absorption of crack energy and alleviation of internal stresses during LPBF, effectively reducing crack initiation and growth. Due to increased curvature forces and intense Marangoni convection at the top of the molt pool, particle collision intensifies, leading to the tendency of HEA particles to agglomerate at the upper part of the molt pool. However, this phenomenon can be effectively alleviated in the remelting process of subsequent layer deposition. Furthermore, a portion of the HEA particles partially dissolves and sinks into the molten pool, acting as heterogeneous nucleation particles, inducing the formation of equiaxed eutectic and leading primary phase nucleation. Some HEA particles diffuse into the lamellar ternary eutectic structures, further promoting the refinement of eutectic microstructures due to increased undercooling. The innovative doping of HEA particles has effectively facilitated the fabrication of turbine-structured, conical, and cylindrical ternary eutectic ceramic composite specimens with diameters of about 70 mm, demonstrating significant developmental potential in the field of ceramic composite manufacturing.

Three-dimensional super-resolution crack imaging in industrial manufactured components: A truncated correlation photothermal coherence tomography approach

The challenge of detecting cracks in powder metallurgy (PM) components has been a topic of interest for many years, with no practical commercial solution currently in place. This study employs enhanced truncation-correlation photothermal coherence tomography (eTC-PCT) to visualize 3D cracks within PM automotive parts. Through the application of effective diffusion-wave reversal techniques, blurred infrared thermophotonic images of subsurface defects (cracks) in (“green”) compressed metal PM components were restored to their original geometric resolution over the entire depth range. This approach enabled the creation of 3-dimensional depth-resolved photothermal tomographic images and cross-sectional mappings of cracks. The developed technique reveals the precise spatial dimensions of surface and subsurface cracks, reaching depths of down to 3 mm (not an upper limit) that conventional thermal imaging cannot access due to limitations imposed by the depth-integrated nature of conventional thermal-wave imaging, the properties of PM materials, and the physics of spreading diffusion. The super-resolution method was further applied to a sintered automotive part, specifically validating the efficacy of eTC-PCT for non-destructive imaging (NDI) in manufactured automotive components. Diffusion reversal imaging shows promise as a non-destructive testing (NDT) tool, with potential applications in a wide range of manufactured products, including both the green and sintered stages of automotive component production.