Tip Deflection Research Articles

Studying and analysis of deformation and stresses in horizontal-axis wind turbine using fluid-structure interaction method

Fluid-structure interaction (FSI) studies have become an important tool in the development of wind turbine blades as well as for analyzing and optimizing Horizontal Axis Wind Turbine (HAWT). The most essential elements for estimating the turbine blade strength to withstand extreme wind loads and aerodynamic performance are the blade deformation and the associated stresses. This study aims to compare the strength and analyze the deformation behavior of two models of HAWT blades. A three-dimensional model was created and loaded into a Finite Element (FE) model for analysis. The Computational Fluid Dynamics (CFD) investigation was coupled with the structural model using one-way FSI. In this article, the effect of the aerodynamics on the blade surface of a small HAWT has been studied numerically and experimentally. The airfoil used for the blade profile is S826 airfoil. To provide an appropriate displacement for static measurements, the blade in the experimental investigation is made of thermoplastic polyurethane material (TPU). It is noted that the current experimental findings verify the simulation results, and a comparison between the simulations and the experimental findings reveals a reasonable agreement. The numerical simulations are also implemented on a HAWT epoxy E-glass unidirectional (EEGUD) material. It can be concluded from this study that the blade deformation and stress on the blades are related to the wind speed. The deformation along the span length exhibits nonlinear variation that gradually increases from the blade root and reaches its maximum at the blade tip position. The tip deflection and equivalent stress were found to increase with an increase in wind speed. The dynamic analysis at different tip speed ratios shows the highest deformation at λ = 4, for wind speed of 20 m/s.

Topology optimization and experimental validation of mass-reduced aircraft wing designs

Development and evaluation of a novel design of mass reduced aircraft wing ribs through topology optimization is reported herein. For comparison, the same examination is performed on ribs with normal internal geometry. The wing rib design is based on the Gulfstream G650 transonic jet. The rib is divided into three segments for analysis based around the positions of the two spars. Only the center section of the rib is mass optimized, while the leading and trailing edges of the ribs are kept solid. Methodology in this study includes the k-Ω shear stress transport turbulence model computational fluid dynamic simulation as well as static and transient finite element simulations. The optimized wing rib is found to be between 8% and 15% lighter than traditional wing ribs depending on configuration. Simulation of the wing showed a tip deflection of 13.8 cm upward at an angle of 1.1°. An experimental scaled model of the optimized wing subjected to near identical bending loads as identified in the FEA simulation is applied to validate stress concentrations and performance. It is found that in the simulations, average stress never exceeded the factor of safety prescribed by the FAA. While the average factor of safety on the full computational model was 2.649, the average factor of safety on the experimental model was 9.185. Four strain gauges attached to the experimental model are used to compare the strains at similar locations on the computational model. The experimental results validate the CFD simulation results with acceptable tolerances.

The impact of extreme wind conditions and yaw misalignment on the aeroelastic responses of a parked offshore wind turbine

As global energy demands rise and the urgent need to reduce carbon emissions, offshore wind energy technology has evolved rapidly, becoming a vital component of the world’s energy portfolio. However, offshore wind turbines face new challenges due to complex marine environments. Under extreme conditions such as strong winds and yaw misalignment, parked wind turbines exhibit complex aerodynamic and structural responses that significantly differ from those in normal operating conditions. These responses, crucial to the integrity and safety of wind turbines, demand thorough analysis. This article presents an in-depth aeroelastic analysis of a parked 5 MW offshore wind turbine using a sophisticated and precise numerical model. It explores the impacts of incoming wind speed and yaw misalignment on the aerodynamic loads and structural behaviors of the wind turbine. The findings indicate that gravity plays a significant role in blade structural responses for a parked wind turbine. Additionally, higher wind speeds elevate aerodynamic forces, leading to more pronounced fluctuations in root forces and tip deflections. The increase in wind speed triggers and exacerbates high-frequency edgewise vibrations of the blade, further leading to fluctuations and instability in the loads. The study also reveals that yaw misalignment causes the AOA changes significantly over time, and generates intermittent fluctuations in lift and drag, leading to extra blade vibrations with the maximum amplitude exceeding 10% of the blade length. This research enhances the current understanding of the operational safety of offshore wind turbines, particularly under extreme conditions. It aims to provide valuable insights and guidance for researchers and developers in designing and monitoring the performance of offshore wind turbines, ensuring their resilience and efficiency in challenging environments.

Tracking of Bristle Tip Deflections To Demonstrate Blow-Down in Brush Seals

Tracking of Bristle Tip Deflections To Demonstrate Blow-Down in Brush Seals

Structural Optimization of a Large-Scale 3D-Printed High-Altitude Propeller Blade with Experimental Validation

This paper presents a structural optimization of a 3D-printed thermoplastic-core propeller blade for high-altitude unmanned aerial vehicles using a genetic algorithm. It aims to minimize the weight of the blade by creating longitudinal holes and spars and to minimize the blade tip deflection during operation at an altitude of 16 km. The objective is to check the validity of a 3D-printed material modeling approach for large-scale and more complex 3D-printed parts, such as hollow twisted blades. The approach is based on attentively selecting the printing parameters that reduce the anisotropy of the 3D-printed parts. The linear isotropic behavior of 3D-printed Polylactic Acid and Acrylonitrile Butadiene Styrene M30 tensile samples, which have been tested at ambient and low temperatures (−60°C), is utilized to numerically predict the experimental deformation and natural frequencies of 3D-printed substitute and twisted full blades with good accuracy. The validated linear isotropic model of each material is then used to evaluate the objectives and the constraints of the two-objective optimization process using one-way fluid–structure interaction. Four optimized blades have been selected from the Pareto fronts as candidates, printed, and tested in bending and vibration. The numerical and experimental results of the candidate blades in terms of deformation and natural frequencies are in good agreement, proving the validity of the present macroscale approach for large-scale hollow twisted blades.

Effect of interface type on deformation mechanisms of γ-TiAl alloy under different temperatures and strain rates by molecular dynamics simulation

Crystalline interface plays a significant role in strengthening lamellar γ-TiAl alloys through reconciling the strength and ductility. Herein, the effects of temperature and strain rate on the tensile deformation of three lamellar γ-TiAl interface models are investigated by molecular dynamics simulations. The three interfaces, pseudo twin (PT), rotational boundary (RB), and true twin (TT), exhibit different tensile responses due to the different interface effects: TT interface only acts as a barrier of dislocation traversing to facilitate crack extension; PT interface acts as both dislocation barrier and emission source and has a stronger release of strain energy than TT interface, retarding the crack extension; RB interface can retard and resist crack extension due to the blunting and deflection of the crack tip and the best interface geometry compatibility. The defect evolution indicates that the elevated temperature suppresses dislocation propagation at low strain rate, while the high strain rate causes small lamellar stacking faults and slit-shaped holes along tensile direction at low temperature. In addition, the dual conditions of high strain rate and low temperature induce the phase transition from FCC to BCC and then BCC to HCP. These findings provide a specific insight to understand the atomistic mechanism of interface-mediated deformation.

Multiphysics modeling and optimization of an innovative shape memory alloy-polymer active composite

Shape memory alloys (SMAs) are a unique class of smart materials capable of recovering significant deformations through temperature variations, making them attractive for adaptive structures and morphing applications. However, integrating SMAs into polymer composites poses significant challenges, such as interfacial delamination and matrix overheating during thermal activation, in addition predicting the stress acting on the SMA during the actuation is pivotal. Addressing these issues is crucial for realizing the full potential of SMA-based active composites in aerospace, automotive, and renewable energy sectors. This study presents a novel multi-material design strategy for SMA-polymer active composites, featuring a rigid PC/ABS layer for mechanical integrity, a soft high-temperature silicone coating for encapsulating SMA wires, and aluminum terminals for wire crimping. A comprehensive multiphysics FEM model was developed to accurately capture the coupled thermo-mechanical response. Extensive experimental characterization and validation were conducted, followed by systematic parametric studies to investigate the effects of critical design parameters on key performance metrics. The developed prototype exhibited remarkable shape morphing capabilities, with a maximum tip deflection of 68 mm (deflection-to-length ratio of 0.4). Excellent agreement between experiments and simulations was achieved, with a maximum error of 1.7 % in tip deflection, validating the accuracy of the multiphysics model. Parametric analyses quantified the trade-offs between geometric parameters, revealing their influence on activation temperature, deflection, SMA wire stress, and fatigue life. Optimal configurations enabling low activation temperatures (<150 °C), low stress levels (<400 MPa), and high predicted fatigue life (>50,000 cycles) were identified. The multi-material design approach effectively addressed common issues in SMA-polymer composites, enabling reliable actuation cycles without damage accumulation. The validated multiphysics model and parametric insights provide a comprehensive framework for optimizing the design and performance of SMA-polymer active composites, paving the way for their widespread adoption in shape morphing applications. Potential implications include the development of adaptive aerodynamic surfaces, deployable structures, and energy-efficient systems across various industries.

Validating low- and high-fidelity simulations of a yawed 8 MW wind turbine against measurements

This paper presents a comparison study of the aerodynamic behavior of an 8 MW wind turbine operating under yawed conditions using field measurements, Blade Element Momentum (BEM) theory and Computational Fluid Dynamics (CFD). Turbulent inflow wind field measurements are used to generate an IEC-compliant turbulence box upstream of the wind turbine that is used within the BEM tool MoWiT and the CFD tool chain by IWES in OpenFOAM. Both simulation approaches take into account blade flexibility using modal reduced, anisotropic beam elements in BEM and Geometrically Exact Beam Therory (GEBT) in CFD. While the focus is being set towards the CFD approach, turbine power output, blade root bending moments and blade tip deflections are analyzed. It is shown that both modeling approaches react differently towards the generated wind field.

The Underwater Berlin Research Turbine: A Wind Turbine Model for Wake Investigations in a Water Towing Tank

The design of a three-bladed horizontal axis research wind turbine for wake investigations is described. The turbine has a rotor diameter of 1.3 m and will be operated in a large water towing tank at a submergence depth of 2.5 m, yielding 3.3 % blockage. The test rig is configured to allow for underwater-stereo-particle-image-velocimetry measurements of the near and the far wake at chordwise Reynolds numbers approaching 700 000. The low-Reynolds number airfoil SG6040 is selected to constitute the rotor blades. Cavitation-free operation is assured by assigning a rated angle of attack of 1°. The blades are designed to maintain a constant circulation along the blade span and to minimize tip deflections. The blade pitch angles are adjustable. Various blade designs, with and without passive flow control devices, can be tested by replacing individual blade sections. This eliminates the need for multiple sets of blades. Sensors for acquiring the turbine’s thrust, torque, rotational speed, the azimuthal positions of the blades, and the imposed blade root bending moments are incorporated into the design. The wind turbine simulation suite QBlade is utilized to simulate the turbine characteristics. A model of the entire test rig is derived, representing its structural properties. Results from the analytical verification of the structural model are provided. QBlade is utilized to analyze the test rig design by imposing design loads and calculating the modal properties.

Experimental investigation of rear flexible flaps interacting with the wake dynamics behind a squareback Ahmed body

We have conducted an experimental study on the use of rear flexible vertical flaps as adaptive solutions to reduce the drag of a squareback Ahmed body, and on the fluid–structure interaction mechanisms at the turbulent wake. To that aim, wind tunnel experiments were conducted to compare the performance of various configurations including the baseline body, the body with rigid flaps and with flexible flaps. These configurations were tested under different aligned and cross-flow conditions. The results reveal that the flexible adaptive devices effectively reduce the drag within for low values of the dimensionless stiffness quantified through the Cauchy number, Ca. Thus, the two-dimensional deformation of the flexible flaps, which undergo progressive inwards reconfiguration (with an averaged tip deflection angle of Θ≃4°), reduces the bluffness of the flow separation at the body base, thus shrinking the recirculation region. This reconfiguration leads to increased base pressure, resulting into a 8.3% decrease in the global drag, CD, under aligned conditions. Similar drag reductions are observed under yawed conditions.Two regimes are identified in terms of the coupled fluid–structure dynamics. For low Ca, the passive reconfiguration of the flaps include small amplitude, periodic oscillations corresponding to the first free deformation mode of a cantilevered beam. Alongside these weak oscillations, the flaps are deformed guided by the changes in the value of the horizontal base pressure gradient, depicting bi-stable behavior which is caused by the synchronization between the Reflectional Symmetry Breaking (RSB) mode, typically present in the wake of three-dimensional bluff bodies, and the flaps deformation. For higher values of Ca, the flexible flaps deflect inwardly by about Θ≃20° on average, but exhibit vigorous oscillations combining the first and second free deformation modes of a cantilevered beam. These large amplitude oscillations excite the flow separation at the model’s trailing edges, leading to significant fluctuations in the separated shear layers and a consequent 31% increase in the global drag. Under yawed conditions, the flaps responses for large values of Ca are different due to the asymmetry of the corresponding recirculation region.

Structural factors influencing the clinical performance of 0.025-inch guidewires for pancreatobiliary endoscopy: An experimental study.

Background and study aims To develop a pancreatobiliary endoscopic guidewire with good clinical performance, an understanding of its structure is necessary. This study aimed to investigate the structural factors influencing the clinical performance of pancreatobiliary endoscopic guidewires. Methods Eight types of 0.025-inch guidewires were evaluated. The following structural properties were measured: tip length, tip deflection height, tip weight (TW), ratio of tip core weight to TW, shaft coating type (flat or uneven), outer diameter, and core wire diameter (CWD). Four performance tests were conducted to evaluate shaft stiffness as bending force (BF), shaft lubricity as friction force (FF), torque response as torque response rate (TRR), and seeking ability as total insertion success (TIS) in a technical test using a 3D bile duct model. The correlation coefficients of each variable were analyzed. Results The BF and CWDs were strongly correlated, as well as the FF and CWDs and BF. Among the guidewires with similar CWDs, the guidewires with uneven coating had significantly lower FF than those with flat coating. The TRR was strongly correlated with the CWDs; furthermore, guidewires with lower FF had better TRR. TIS was strongly correlated with the TRR, TWs, and ratio of the tip core weight to TW. Conclusions CWD affects shaft stiffness; CWD and coating type affect shaft lubricity and torque response. Because TRR and TW are correlated with seeking ability, an appropriate combination of core wire thickness, TW, and coating design is required to develop a guidewire with good seeking ability.

Pulsed heating of the self-actuated cantilever: a one-dimensional exact solution investigation of non-axial temperature gradients

Self-actuated bimorph cantilevers are implemented in a variety of micro-electro-mechanical systems. Their tip deflection relies on the unmatched coefficients of thermal expansion between layers. The thermal bimorph phenomenon is dependent on the temperature rise within the cantilever and, while previous studies have investigated variations in the thermal profile along the cantilever length, these have usually neglected variations in the thermal profile along the cantilever thickness. The current study investigates the thermal distribution across the thickness of the cantilever. The exact closed form solution to the one-dimensional problem of heat conduction in the composite (layered) domain subjected to transient volumetric heating is developed using the appropriate Green’s function. This solution is applied to a one-dimensional case study of a 3-layer cantilever with an Aluminium heater, a silicon dioxide resistive layer, and a silicon base layer. The aluminium heater experiences volumetric heating at a rate of 0.2 mW/μm3 of 5 μs duration at 100 μs intervals (10 kHz with a 1/20 duty cycle). Benchmark solutions of the temperature at select times and positions are provided. It is shown that there are negligible temperature gradients across the cantilever thickness during the heating and the first ~ 5 μs afterward. These short-lived temperature differences are positively biased with the unmatched thermal expansion coefficients between the layers, though their relative influence on bending is not clear. A simple parametric analysis indicates that the relative magnitude of the temperature differences across the cantilever (compared to the overall temperature) decreases substantially with increasing duty cycle.

Enhancing Axial Flow Fan Performance in Air-Cooled Condensers: Tip Vortex Manipulators and Comparative Analysis of Numerical Simulation and Experimental Testing

Abstract Direct dry-cooled power plants typically operate numerous large-diameter axial flow fans in air-cooled condensers (ACCs) to facilitate the condensation of steam in the plant's thermodynamic cycle. Enhanced fan efficiency may, at scale, lead to significant parasitic power reductions and subsequent increases in plant power output. The performance of these fans may be increased by adding blade-tip modifications, which act to control blade-tip leakage flow. Previous studies have shown that manipulating the tip leakage vortex (TLV) increases the blade-to-air momentum transfer and stabilizes the air flow structures as it traverses the fan blade. This paper takes a step toward the development of improved tip vortex manipulators for an ACC fan. Three-dimensional computational fluid dynamics (CFD) simulations, and experimental testing of the modified and unmodified fan within an ISO test facility are performed. The results are then utilized to assess the accuracy of the simulation model, visualize the manipulated flow structures at the blade tip, and ultimately quantify the effect of the endplate designs on fan performance. Excellent correlation between numerical and test results for the unmodified fan is observed, and the benefit of blade-tip modification on fan performance is again confirmed experimentally. The simulation model, however, fails to predict improvements in fan performance under modification, and simulated tip leakage flows are investigated for clarification. It is hypothesized that deflection of tip endplates under operation account for differences between simulation and experiment, and that fluid–structure interaction analyses could potentially resolve discrepancies.

Advancements and Challenges in Robot-Assisted Bone Processing in Neurosurgical Procedures.

Practical applications of nerve decompression using neurosurgical robots remain unexplored. Our ongoing research and development initiatives, utilizing industrial robots, aim to establish a secure and efficient neurosurgical robotic system. The principal objective of this study was to automate bone grinding, which is a pivotal component of neurosurgical procedures. To achieve this goal, we integrated an endoscope system into a manipulator and conducted precision bone machining using a neurosurgical drill, recording the grinding resistance values across 3 axes. Our study encompassed 2 core tasks: linear grinding, such as laminectomy, and cylindrical grinding, such as foraminotomy, with each task yielding unique measurement data. In linear grinding, we observed a proportional increase in grinding resistance values in the machining direction with acceleration. This observation suggests that 3-axis resistance measurements are a valuable tool for gauging and predicting deep cortical penetration. However, problems occurred in cylindrical grinding, and a significant error of 10% was detected. The analysis revealed that multiple factors, including the tool tip efficiency, machining speed, teaching methods, and deflection in the robot arm and jig joints, contributed to this error. We successfully measured the resistance exerted on the tool tip during bone machining with a robotic arm across 3 axes. The resistance ranged from 3 to 8 Nm, with the measurement conducted at a processing speed approximately twice that of manual surgery performed by a surgeon. During the simulation of foraminotomy under endoscopic grinding conditions, we encountered a -10% error margin.

Influence of passive deformation in the lift coefficient of a NACA0012 wing model

The extensive use of lightweight materials in aerial vehicle wings involves structural flexibility phenomena that generate non-negligible deformation effects. This influence is not restricted to big aircraft but also plays a role in smaller aeroplanes and Unmanned Aerial Vehicles (UAVs). Here, we conduct wind tunnel experiments to analyze the effect of passive deformation on the wing model lift slopes. To isolate the deformation effect, we compare rigid wings with a NACA0012 airfoil imposing a prescribed spanwise deformation. We study three levels of deformation: non-deformed, around 2% and 4.5% of tip deflection. Also, we consider the effect of the wing length by using three different semi-aspect ratios (1, 2, and 4), so a total of nine rigid wing models have been analyzed for a range of Reynolds number from 80×103 to 160×103. Deformed wing models show an increase in lift coefficient compared to non-deformed wing cases. Both deformation levels exhibit a qualitatively similar lift increment. A correlation to predict lift coefficient slope in a flat plate is adapted for a NACA0012 airfoil and validated using our experimental results and literature data. The adjusted correlation can quantify the deformation effect on the lift slope, which is comparable to using a slightly longer wing model.

A correlation study on piezo-embedded carbon fibre reinforced polylactic acid composite: Experimental and numerical modelling

In this research work, a piezoelectric sensor and actuator model was designed. Carbon fibre-reinforced polylactic acid (CF/PLA) composites were fabricated using the fused deposition modelling (FDM) technique using many parameters to achieve this goal. For instance, the primary key parameters were 0.1 mm (layer height) and 25 mm/s (print head). Besides, the fabricated samples were subjected to a tensile study. Besides, MATLAB® Partial Differential Equation (PDE) tool was used to develop a finite element analysis (FEA) model for the piezoelectric actuator using the experimentally tested results. The MATLAB® was also used to examine the geometry and tip deflection. The experimental works were carried out to measure the sample’s strain using piezoelectric sensors. This approach could be used to establish the accuracy of the model. The CF/PLA composites were fabricated using 20 wt.% of reinforcements. The experimental results and finite element simulation were good agreement on results. Results reported that the deflections of 6.5765 mm, 5.197 mm, and 7.6328 mm, respectively embedded with PZT 5J, PZT 5H, and PZT 5A.

The synergistic role of virtual coaching with simulation-based mastery learning for upper endoscopy.

Our simulation-based mastery learning (SBML) curriculum, delivered in person, has been shown to successfully train novices in structured esophagogastroduodenoscopy (EGD). SBML with virtual coaching (VC) has the potential to improve the effectiveness and efficiency of endoscopy training and expand access to trainees from around the world. We share our observations conducting an EGD training course using SBML with VC. We conducted a 1-week virtual SBML course for novice trainees across seven academic centers in the USA and Asia. The cognitive component was delivered using an online learning platform. For technical skills, a virtual coach supervised hands-on training and local coaches provided assistance when needed. At the end of training, an independent rater assessed simulation-based performance using a validated assessment tool. We assessed the clinical performance of 30 EGDs using the ASGE Assessment of Competency in Endoscopy tool. We compared the trainees' scores to our cohort trained using in-person SBML training using non-inferiority t-tests. We enrolled 21 novice trainees (mean age: 30.8 ± 3.6 years; female: 52%). For tip deflection, the trainees reached the minimum passing standard after 31 ± 29 runs and mastery after 52 ± 37 runs. For structured EGD, the average score for the overall exam was 4.6 ± 0.6, similar to the in-person cohort (4.7 ± 0.5, p = 0.49). The knowledge-based assessment was also comparable (virtual coaching: 81.9 ± 0.1; direct coaching: 78.3 ± 0.1; p = 0.385). Over time, our novice trainees reached clinical competence at a similar rate to our historical in-person control. VC appears feasible and effective for training novice gastroenterology trainees. VC allowed us to scale our SBML course, expand access to experts, and administer SBML simultaneously across different sites at the highest standards.

An airbrush 3D printer: Additive manufacturing of relaxor ferroelectric actuators

The additive manufacturing of electroactive polymer (EAP) devices poses significant challenges due to their distinct structure and dissimilar properties of their constituent materials. It requires deposition of multiple functional materials with different properties, achieving μm-scale resolution in layer thickness, and executing incremental deposition and curing steps while preserving the previously deposited functional material layers. This study introduces an airbrush 3D printer concept and employs it for fabricating EAP transducers. An airbrush 3D printer was constructed by adapting a standard extrusion printer platform and integrating it with a two fluid atomizer (i.e. an airbrush) as the deposition tool. A process was developed for printing of the bending P(VDF-TrFE-CTFE) actuators with carbon black electrodes, and actuators with a single and dual EAP layers were fabricated. The airbrush printer attained in-plane resolution of 0.5mm, thickness resolutions of 0.63 μm and allowed atomizing up to 7% P(VDF-TrFE-CTFE) solutions. The 18 mm × 4 mm EAP actuators achieved 340μm (440 Vpp) and 3.7 mm (400 Vpp, 104 Hz) tip deflections respectively in quasi-static and resonant operation. Airbrush printing therefore proved to be a robust method for printing precursor materials with a wide range of properties, and is anticipated to be a versatile approach for printing other passive and stimuli-responsive materials and devices.

3D multiscale dynamic analysis of offshore wind turbine blade under fully coupled loads

Wind turbine blades are typically sophisticated structures with complex geometry and composite layup. The realistic loads acting on blades serviced in harsh offshore environments are fully coupled dynamic loads involving wind, wave, current, servo-control, gravity and other inertial loads. This work presents an easy-to-implement methodology for the time-domain detailed analysis of three-dimensional (3D) blade structure, by combining fully coupled dynamic simulator and general finite element program. As a practical example subjected to multiple marine environmental loadings, one of the rotating composite blades atop a 5-Megawatt (MW) monopile-supported offshore wind turbine (OWT) in soft clay is used for verifying this method step by step, and the effect of rotation and foundation flexibility on blade behaviours is explored. Good agreement between OpenFAST and proposed method in tip deflections and root reaction loads is visible from validation results, and the recommendations on how to further improve this method in future iterations are made. Subsequently, based on stress-time history of blade composite layups, time-domain 3D multiscale analysis including the failure evaluation for layers in outer shell and shear webs using Tsai-Wu strength criteria, as well as the fatigue damage assessment of carbon spar caps was performed.

Martensite content effect on fatigue crack growth and fracture energy in dual‐phase steels

AbstractThe effect of different microstructural factors on crack growth and fatigue fracture mechanisms in dual‐phase (DP) steels has yet to be fully understood. The present research examines the relationship between crack growth, microstructure, and fracture mechanisms. The samples were intercritically annealed at different temperatures to produce three different martensite volume fractions (MVFs). The results show that the mechanical incompatibility of ferrite and martensite promotes continuous crack tip deflection. MVF increases are associated with elevated fracture tortuosity, more significant fracture energy surface formation, and higher Paris law exponent m values. The interaction of the microstructure with the crack tip, the strain energy density, and the softening caused by secondary microcrack propagation are all illustrated by Electron backscatter diffraction (EBSD) maps. Increasing MVF promotes slow crack growth and a fracture energy increase of 22.9% between the as‐received and heat‐treated steels.