Digital Image Correlation Research Articles

Experimental study on the Mode l fracture toughness of frozen silty clay incorporating Digital image correlation

To investigate the effects of initial moisture content and temperature on the Mode I fracture toughness (KIc) of frozen silty clay, a series of three-point bending tests were conducted. Rectangular specimens with prefabricated cracks were tested, and digital image correlation (DIC) technology was employed to analyze the microscopic characteristics at the crack tip. The results indicate that the Mode I fracture toughness of frozen silty clay increases with decreasing temperature and increasing initial moisture content. Temperature governs the failure mode, with plastic failure predominantly occurring at high temperatures and brittle failure at low temperatures. Based on the load–displacement curves and DIC recordings, the macroscopic fracture process of the specimens can be categorized into three stages: elastic deformation, formation of the failure surface, and specimen failure. Additionally, the crack propagation process can be further divided into three stages: initiation and development of microcracks, transition from microcracks to macroscopic cracks, and rapid development of macroscopic cracks. These findings provide critical insights for slope stability research in cold regions and offer new perspectives for engineering design and construction in similar environments.

Multiscale evaluation of sand-geomaterial interface shear response in terms of material geometry effects

This study evaluates the effects of particle and surface geometric features on the interface shear behavior of sand-geomaterial. Particle shape and size were adjusted for the sand, and surface roughness form and height were set for the geomaterial part. 3D printing technology was used to produce geomaterials in the desired form. A custom-made transparent interface shear box was developed to perform digital image processing. For macroscale response, peak and residual strengths and dilation angle were measured. Sliding percentage and shear band thickness were determined from digital image correlation analyses for the mesoscale response. The experimental results showed that the macroscale response parameters increased as the overall regularity of the sand particles decreased. The increase in mean particle size and roughness height led to an increase in macroscale parameters. Digital image correlation analyses showed that the sliding percentage had an inverse correlation with the shear band thickness in terms of the particle shape and the roughness height effects. The roughness form controlled the trend of mean particle size effects on the sliding percentage. Overall, the mesoscale parameters revealed the traces of interlocking response, particle kinematics, and the failure mechanism in the interface region. Thus, a bridge was established between meso- and macro-scale responses.

Anisotropic Fracture Evolution and Size Effect of the Fracture Process Zone in Laminated Shales Derived from Digital Image Correlation

Anisotropic Fracture Evolution and Size Effect of the Fracture Process Zone in Laminated Shales Derived from Digital Image Correlation

Tailoring smart hydrogels through manipulation of heterogeneous subdomains

The mechanical interactions among integrated cellular structures in soft tissues dictate the mechanical behaviors and morphogenetic deformations observed in living organisms. However, replicating these multifaceted attributes in synthetic soft materials remains a challenge. In this work, we develop a smart hydrogel system featuring engineered stiff cellular patterns that induce strain-driven heterogeneous subdomains within the hydrogel film. These subdomains arise from the distinct mechanical responses of the pattern and film domains under applied mechanical forces. Unlike previous studies that incorporate reinforced inclusions into soft matrices to tailor material properties, our method manipulates the localization, integration, and interaction of these subdomain building blocks within the soft film. This enables extensive tuning of both local and global behaviors. Notably, we introduce a subdomain-interface mechanism that allows for the concurrent customization and decoupling of mechanical properties and shape transformations within a single material system—an achievement rarely accomplished with current synthetic soft materials. Additionally, our use of in-situ imaging characterizations, including full-field strain mapping via digital imaging correlation and reciprocal-space patterns through fast Fourier transform analysis of real-space pattern domains, provides rapid real-time monitoring tools to uncover the underlying principles governing tailored multiscale heterogeneities and intricate behaviors.

Integrated Control of Thermal Residual Stress and Mechanical Properties by Adjusting Pulse-Wave Direct Energy Deposition

Directed energy deposition with laser beam (DED-LB) components experience significant residual stress due to rapid heating and cooling cycles. Excessive residual tensile stress can lead to cracking in the deposited sample, resulting in service failure. This study utilized digital image correlation (DIC) and thermal imaging to observe the in situ temporal evolution of strain and temperature gradients across all layers of a deposited 316 L stainless steel thin wall during DED-LB. Both continuous-wave (CW) and pulsed-wave (PW) laser modes were employed. Additionally, the characteristics of thermal cracks and geometric dislocation density were examined. The results reveal that PW mode generates a lower temperature gradient, which in turn reduces thermal strain. In CW mode, the temperature–stress relationship curve of the additive manufacturing sample enters the “brittleness temperature zone”, leading to the formation of numerous hot cracks. In contrast, PW mode samples are almost free of cracks, as the metal avoids crack-sensitive regions during solidification, thereby minimizing hot crack formation. Overall, these factors collectively contribute to reduced residual stress and improved mechanical properties through the adjustment of pulsed-wave laser deposition.

Experimental study on mechanical properties of 3D Printed layered rock like materials

Layered rocks are prevalent in the Earth’s crust and are frequently encountered in underground engineering construction. Due to their pronounced anisotropy, the deformation and failure mechanism of layered rock are complex. Laboratory tests are an effective way to study these mechanisms. However, natural layered rocks present challenges, such as difficult sampling and large discreteness. Additionally, current methods for creating layered rock models are often costly or lack precision, limiting research into their mechanical properties. In this study, a 3D printing process using wet material extrusion was adopted, with a wide range of material options and low production costs. Five layered model samples with bedding dip angles of 0°, 30°, 45°, 60° and 90° were printed using this method. Uniaxial compression tests were conducted, supplemented by digital image correlation (DIC) to capture detailed stress–strain data and failure patterns. The results demonstrate that the mechanical properties of the 3D-printed samples closely resemble those of natural layered rocks and exhibit significant anisotropy. This approach presents a new cost-effective method for studying the mechanical behavior of layered rock.

Investigation of Mechanical Properties and Microstructural Evolution in Pure Copper with Dual Heterostructures Produced by Surface Mechanical Attrition Treatment

Heterostructured materials consist of heterogeneous zones with dramatic variations in mechanical properties, and have attracted extensive attention due to their superior performance. Various heterostructured materials have been widely investigated in recent years. In the present study, a combination of two different types of heterogeneous structures, a surface bimodal structure and gradient structure, was designed using the traditional surface mechanical attrition treatment (SMAT) method in pure copper, and the mechanical properties and microstructural evolution of dual-heterostructure Cu were studied in depth. In total, 100 stainless steel balls with a diameter of 6 mm were utilized to impact the specimen surface at room temperature for a short period of time. In this work, the sample surface was divided into hard areas and soft areas, along with a roughly 90 μm gradient structure in the cross-sectional direction after 30 s of SMAT processing. After the partial SMAT processing, lasting 30 s, the strength increased to 158.0 MPa and a considerable ductility of 25.7% was sustained, which overcomes the strength–ductility trade-off. The loading–unloading–reloading (LUR) test was utilized to measure the HDI stress, and the result showed that the HDI stress of the partial SMAT sample was much higher than the annealed one, especially for the Cu-SMAT-30S specimen, the strength of which increased from 80.4 MPa to 153.8 MPa during the tensile test. An in situ digital image correlation (DIC) investigation demonstrated that the strain developed stably in the Cu-SMAT-10S specimen. Furthermore, electron backscatter diffraction (EBSD) was carried out to study the microstructural evolution after partial SMAT processing; the KAM value increased to 0.34 for the Cu-SMAT-10S specimen. This research provides insights for the effective combination of superior strength and good ductility in dual-heterostructure materials.

Fatigue life prediction of composite materials using strain distribution images and a deep convolution neural network

The damage process of composite materials, such as short fiber-reinforced plastics (SFRP), is complex. Therefore, it is necessary to accurately represent the damage process in fatigue life prediction. Herein, fatigue life prediction was conducted by combining the digital image correlation method, which is a non-destructive testing technique, with a convolutional neural network (CNN), using Xception as the network architecture. High prediction accuracy was obtained when training and testing were performed on the same SFRP specimens. In contrast, using different specimens for training and testing resulted in lower accuracy. This issue may be improved by increasing the number of specimens. The regions of interest in the model were visualized by Gradient-weighted Class Activation Mapping. Notably, the model indicated the breaking point as the region of interest from the early stages of the test. The breaking point was identified at an earlier stage by the CNN than by visual inspection, demonstrating the potential for a new method of damage observation.

Dual‐Modal Sensing Skin Adaptive to Daylight, Darkness, and Ultraviolet Light for Simultaneous Full‐Field Deformation Measurement and Mechanoluminescence Responses

AbstractMechanoluminescence (ML) and digital image correlation (DIC) have emerged as promising optical methods to visualize and measure deformation fields. In this study, a dual‐modal sensing skin, called the ML‐DIC skin is introduced, that is capable of emitting ML and facilitating DIC measurements under various lighting conditions, including daylight, night or darkness, and UV irradiation. Four ML‐DIC skins are fabricated with or without carbon nanotubes (CNTs) using a composite powder consisting of SrAl2O4: Eu,Dy (SAO), and acrylic resin, with CNT milling times of 48, 72, and 96 h for three of four skins, respectively. DIC measurements are performed under multiple lighting conditions for measuring photoluminescence, persistence luminescence, and reflection. Uniaxial tension tests demonstrate the superior performance of ML‐DIC skins with CNTs compared with pristine SAO skins, with the skin subjected to 48 h of CNT dispersion exhibiting optimal performance. Further investigations focus on ML emission and DIC measurements near the crack‐tip vicinity of static and propagating cracks as well as on surfaces above subsurface cracks. The integration of ML and DIC techniques offers a versatile approach for comprehensive deformation analysis applicable to diverse environments, with implications for materials science, engineering, and structural health monitoring.

Investigation on fatigue damage of buton rock asphalt mixtures using semi-circular bending (SCB) and digital image correlation (DIC) techniques

The fatigue performance evaluation indices of Buton rock asphalt (BRA) modified asphalt mixture struggles to accurately characterize damage evolution process under repeated loads of the traffic. This study employs digital image correlation (DIC) technology to assess the fatigue behavior of BRA modified asphalt mixture, quantify the correlation between macroscopic response and local deformation, and verify the accuracy of evaluation indices. By capturing strain and displacement fields, the fatigue damage evolution of BRA modified asphalt is analyzed. Based on fracture mechanics theory, BRA’ s improvement of fatigue performance is quantified. Results show that vertical displacement captured by DIC can divide the three stages of fatigue cracking. The global horizontal strain(GExx)and cumulative horizontal strain(CExx) proposed in this study better characterize the nonlinear fatigue damage evolution compared to horizontal strain(Exx). Adding BRA delays crack initiation, reduces propagation rate, and enhances fatigue performance. Strain field evolution was quantitatively analyzed, and horizontal strain density(DE) and global horizontal strain density(GDE) were proposed as fatigue damage indicators. At the same load level, these indicators in BRA modified asphalt mixture, both pre- and post-aging, exceeded those of neat asphalt mixture. These findings provide a novel and accurate approach for evaluating the fatigue damage behavior of BRA modified asphalt mixture, laying the foundation for future performance-based designs.

Experimental study on the compression and shear deformation evolution of coal pillar dam samples

To understand the mechanical properties and deformation failure patterns of coal pillar dams in gently inclined coal seam mine underground reservoirs, compression-shear coupling tests with variable angles were conducted on coal pillar dam samples under different saturation states. The digital image correlation (DIC) technique was utilized to obtain the deformation patterns of the displacement field throughout the compression-shear failure process of the samples. Numerical simulations were used to perform a comparative analysis and validation of the experimental results. The results indicated that the load-bearing capacity of the coal pillar dam samples decreased by 12.8–17.4% under water-saturated conditions. For every 5° increase in the inclination angle, the load-bearing capacity of the coal pillar dam samples decreased by an average of 3.53%. The normal stress and shear stress on the shear surface of the saturated samples were both lower than those of the natural samples, and both exhibited a linear variation with increasing inclination angle. The deformation evolution of the coal pillar dam samples under different test conditions exhibited similarity. The initial positive and negative displacement extremities in the horizontal direction were located at the lower right and upper left corners of the samples, respectively. Ultimately, the displacement field of the samples showed a pattern of smaller displacements at the top and larger displacements at the bottom, with negative values at the top and positive values at the bottom, distributed along the direction of the sample’s bedding. The saturated state and the increase in inclination both had a weakening effect on the load-bearing performance of the samples but had a relatively small impact on the differences in the displacement field deformation patterns. The research results can provide a reference for the study of the stability of coal pillar dams under similar conditions.

Experimental method for internal deformation measurement of 3D solids with embedded cracks based on 3D printing and digital speckle techniques

Quantification of the internal deformation of fractured solids such as rock masses under external loads, especially the deformation around internal fractures, is crucial for understanding and predicting the failure of fractured solids. However, it is very difficult to achieve the goal using conventional experimental methods. In this study, we proposed a novel internal deformation measurement method based on three-dimensional (3D) printing and digital speckle techniques. The 3D printing technology was applied to fabricate a 3D transparent model with an embedded elliptical crack and to set a speckle pattern on the internal section of the transparent model. The digital image correlation (DIC) method was used to determine the internal deformation field of the 3D fractured model. The measured displacements and strains of the internal sections in the fractured model were compared with the numerical simulation results. The comparison indicates that the proposed experimental method can well determine the deformation inside the 3D model. This built-in speckle method can realize real-time observation of the internal deformation of a 3D solid model in a non-contact and non-destructive manner.

Seismic behavior of resilient concrete column-base connection with SMA bolts and RSPs

This paper presented a novel resilient concrete column-base connection with shaped memory alloy (SMA) bolts and rectangular slotted plates (RSPs) to achieve the demountable and recoverable capabilities in precast concrete columns. Quasi-static tests were conducted on one monolithic and three resilient concrete connections to investigate the effects of RSP number and yield strength on seismic behavior. Results showed that the resilient connection with both flange and web RSPs had superior lateral capacity, ultimate drift ratio, and energy dissipation compared to the monolithic connection. The resilient connection also exhibited minimal concrete damage and smaller residual deformation. However, low-yield-strength flange RSPs significantly reduced lateral capacity, initial stiffness, and energy dissipation, which should be considered in engineering design. Additionally, adjustment coefficients for rocking interface rotations were determined from digital image correlation (DIC) data using a fitting method. A formula was proposed to predict the flexural capacity of resilient specimens, assuming a plane section in the compression zone. The predictions closely matched the test data, with differences within 10 %, demonstrating the formula's effectiveness. The length, diameter, and material yield strength of the anti-shear steel bar (ASB) had a significant impact on the shear capacity of the interface.

In situ digital image correlation study on the mechanical properties of GH4169 at different temperatures

AbstractGH4169 is a precipitation‐strengthened nickel‐based high‐temperature alloy, and its mechanical behavior at different temperatures is of significant importance for practical applications. Here, an in situ study on the mechanical properties and microstructural evolution of the GH4169 alloy at different temperatures was conducted using scanning electron microscopy in combination with digital image correlation. The results demonstrate the existence of a linear relationship between the local average strain and the macroscopic strain. At temperatures of 20 °C, 100 °C, 180 °C, and 260 °C, the local average strain is 1.96, 2.13, 2.26, and 2.30 times the macroscopic strain, respectively, which shows a clear trend. This indicates that the temperature has a significant influence on the plasticity of the alloy. Additionally, the strain is concentrated below the notch, whereby at a macroscopic strain of 1.7 % at 20 °C and 260 °C, the local maximum strain at the notch is 52 % and 83 %, respectively. Furthermore, when the macroscopic strain reaches 2.12 %, the local maximum strain at the notch is 72 % and 103 %, respectively. At this point, cracks start to initiate and gradually propagate. In situ observations show that at the beginning of the tensile plasticity stage, the plastic strain rate in the grains is twice the rate at the grain boundaries; subsequently, both rates tend to stabilize, and a high‐strain zone appears inside the grains and is coordinately transferred to the surrounding grains through the grain boundaries. The final stage of damage of the alloy consists of perforation fracture, and the presence of a large number of cracked carbides at the fracture results in specimen cracking.

Damage behavior and toughening mechanism of SiCf/SiC-Ti3SiC2 composites: A combination of digital image correlation and acoustic emission

Matrix modification is an effective method to improve the mechanical properties of ceramic matrix composites, while the elucidation of corresponding damage mechanism is essential for the design and engineering application of composites. In this work, Ti3SiC2 particles were introduced into SiC matrix to fabricate Ti3SiC2 modified SiCf/SiC (SiCf/SiC-Ti3SiC2) composites by a hybrid technique of slurry suspension impregnation combined with polymer infiltration and pyrolysis. Compared with SiCf/SiC composites, the flexural strength and modulus of SiCf/SiC-Ti3SiC2 composites were increased by 17.8 % and 61.0 %, respectively. The three-point flexural damage behavior and failure mechanism of composites were systematically investigated and compared by the combination of digital image correlation and acoustic emission techniques. Based on the collaborative analysis of in-situ damage process, matrix micro-zone toughness and fracture morphology, the modification effect and toughening mechanism of Ti3SiC2 were revealed. The improved mechanical properties of SiCf/SiC-Ti3SiC2 composite could be ascribed to the more sufficient matrix cracking before composite failure and the increased matrix fracture energy by microcrack deflection. After matrix modification, the failure mechanism was dominated by the gradual propagation and growth of microcracks until the critical crack size, instead of the fast and unstable propagation of main crack.

Experimental and Numerical Evaluation of Calcium-Silicate-Based Mineral Foam for Blast Mitigation

Cellular materials such as aluminum and polyurethane foams are recognized for their effectiveness in energy absorption. They commonly serve as crushable cores in sacrificial cladding for blast mitigation purposes. This study delves into the effectiveness of autoclaved aerated concrete (AAC), a lightweight, porous material known for its energy-absorbing properties as a crushable core in sacrificial cladding. The experimental set-up features a rigid frame made of steel measuring 1000 × 1000 × 15 mm3 with a central square opening (300 × 300 mm2) holding a 2 mm thick aluminum plate representing the structure. The dynamic response of the aluminum plate is captured using two high-speed cameras arranged in a stereoscopic configuration. Three-dimensional digital image correlation is used to compute the transient deformation fields. Blast loading is achieved by detonating 20 g of C4 explosive set at 250 mm from the plate’s center. The study assesses the mineral foam’s absorption capacity by comparing out-of-plane displacement and mean permanent deformation of the aluminum plate with and without the protective solution. Six foam configurations (A to F) are tested experimentally and numerically, varying in the foam’s free space for expansion relative to its total volume. Results show positive protective effects, with configuration F reducing maximum deflection by at least 30% and configuration C by up to 70%. Foam configuration influences energy dissipation, with an optimal lateral surface-to-volume ratio (ζ) enhancing protective effects, although excessive ζ leads to non-uniform foam crushing. To address the influence of front skin deformability, a non-deformable front skin has been adopted. The latter demonstrates an increased effectiveness of the sacrificial cladding, particularly for ζ values above the optimal value obtained when using a deformable front skin. Notably, using a non-deformable front skin increases maximum deflection reduction and foam energy absorption by up to approximately 30%.

Uncovering the Fracturing Mechanism of Granite Under Compressive–Shear Loads for Sustainable Hot Dry Rock Geothermal Exploitation

Shear-dominated hazards, such as induced earthquakes, pose an escalating threat to the sustainability and safety of the geothermal exploitation. Variations in fault orientations and compression–shear stress ratios exert a profound influence on the failure processes underlying these disasters. To better understand these effects on the shear failure mechanisms of hot dry rocks, mode-II fracturing tests on granites were conducted at varying loading angles (specifically, 55°, 60°, 65°, and 70°). These tests were accompanied by a comprehensive analysis of the mechanical properties, energy dissipation behavior, acoustic emission (AE) responses, and digital image correlation (DIC)-extracted displacement fields. The tensile–shear properties of stress-induced microcracks were discerned via AE characteristic parameter analysis and DIC displacement decomposition, and the mode-II fracture energy release rate was quantitatively characterized. The results reveal that with increasing compression–shear loading angles, the mechanical properties of granites are weakened, and the elastic strain energy at peak stress gradually decreases, while the slip-related dissipated energy increases. Throughout the fracturing process, the AE count progressively climbs and reaches a peak near catastrophic failure, with an upsurge in low-frequency and high-amplitude AE events. Microcrack distribution concentrates aggregation along the shear plane, reflecting the emergent displacement discontinuities evident in DIC contours. Both the AE characteristic parameter analysis and DIC displacement decomposition demonstrate that shear-sliding constitutes the paramount mechanism, and the fraction of shear-oriented microcracks and the ratio of tangential versus normal displacement escalate with increases in shear stress. This analysis is supported by the heightened propensity for transgranular microcracking events observed through scanning electron microscopy. As the shear-to-compression stress increases, the energy concentration along the shear band intensifies, with the gradient of the fitting line between cumulative AE energy and slip displacement steepening, indicative of a heightened mode-II energy release rate. These results contribute to a deeper understanding of the mode-II fracture mechanism of rocks, thereby providing a foundational basis for early warnings of shear-dominant geomechanical disasters, and improving the safety and sustainability of subsurface rock engineering.

Naturalization and evaluation of synthetic random stripes pattern for digital image correlation

Abstract The morphology of speckle patterns commonly used in the Digital Image Correlation (DIC) community can be categorized into artificially generated free shapes and computer-synthesized circular dots. Due to the non-repeatability of manually sprayed patterns, researchers tend to favour code-controlled dot patterns, which exist in two forms: “white dots on a black background” and “black dots on a white background”. However, from the perspective of biological evolution, these two dot patterns can be hybridized “in silico” using the Turing model to create an intermediate form—the “striped-like” pattern. This hybridization significantly improves species identification and environmental adaptability. Although there have been reports on producing stripe patterns based on the kernel-based Turing model, there is no specific speckle pattern generation specification or comprehensive evaluation research for DIC applications. This paper naturalizes a novel striped speckle pattern and a corresponding generation approach. The pattern quality was assessed and compared with circular dots and hand-sprayed speckles. The stripes pattern outperformed the other two forms regarding Mean Intensity Gradient (MIG), q-factor, systematic bias, and random error. Sub-pixel displacement simulation and actual translation test results demonstrate that the proposed striped pattern offers higher precision and robustness in displacement and static strain measurements. Therefore, this striped pattern provides a preferred alternative for DIC technicians.

Global and Local Shear Behavior of the Frozen Soil–Concrete Interface: Effects of Temperature, Water Content, Normal Stress, and Shear Rate

The interface between soil and concrete in cold climates has a significant effect on the structural integrity of embedded structures, including piles, liners, and others. In this study, a novel temperature control system was employed to conduct direct shear tests on this interface. The test conditions included normal stress (25 to 100 kPa), temperature (ranging from 20 to −6 °C), water content (from 10 to 19%), and shear rates (0.1 to 1.2 mm/min). Simultaneously, the deformation process of the interface was continuously photographed using a modified visual shear box, and the non-uniform deformation mechanism of the interface was analyzed by combining digital image correlation (DIC) technology with the photographic data. The findings revealed that the shear stress–shear displacement curves did not exhibit a discernible peak strength at elevated temperatures, indicating deformation behavior characterized by strain hardening. In the frozen state, however, the deformation softened, and the interfacial ice bonding strength exhibited a positive correlation with decreasing temperature. When the initial water content was 16% and the normal stress was 100 kPa, the peak shear strength increased significantly from 99.9 kPa to 182.9 kPa as the test temperature dropped from 20 °C to −6 °C. Both shear rate and temperature were found to have a marked effect on the peak shear strength, with interface cohesion being the principal factor contributing to this phenomenon. At a shear rate of 0.1 mm/min, the curve showed hardening characteristics, but at other shear rates, the curves exhibited strain-softening behavior, with the softening becoming more pronounced as shear rates increased and temperatures decreased. Due to the refreezing of interfacial ice, the residual shear strength increased in proportion to the reduction in shear rate. On a mesoscopic level, it was evident that the displacement of soil particles near the interface exhibited more pronounced changes. At lower shear rates, the phenomenon of interfacial refreezing became apparent, as evidenced by the periodic changes in interfacial granular displacement at the interface.

Enhancement of pin‐bearing behavior of pultruded FRP profiles by multi‐directional fiber architecture design

AbstractThe low resistance of bolted joints in pultruded unidirectional (UD) fiber‐reinforced polymer (FRP) profiles limits the load grade of truss bridges due to shear damage along UD fibers. To address this issue, this study proposes multi‐directional (MD) fiber architecture in FRP profiles to improve the ultimate bearing strength of bolted joints. The digital image correlation shows that the addition of off‐axis fibers in MD FRP profiles prevents shear failure in the UD FRP profile. As a result, the ultimate bearing strengths of MD FRP profiles are enhanced attributed to “off‐axis fiber tie action”. Micro‐computed tomography shows that fiber damage in MD FRP profiles emerged from outer plies, including fiber breakage in 90° and ±45° fibers and fiber kinking in 0° and ±45° fibers. The off‐axis fibers break due to tension when resisting the bearing load in MD FRP profiles. The fiber kinking indicated strength contribution from 0° to ±45° fibers. The fiber breakage and fiber kinking in each ply are dominant in bearing failure instead of delamination, which increases the bearing strength of the pultruded MD FRP profiles. These findings facilitate controlling damage evolution in the pultruded MD FRP profiles and designing high‐resistance bolted joints.Highlights Multi‐directional fibers improved bearing strengths of FRP profiles by 28.5%–33%. Off‐axis fibers bent under pin‐bearing, forming a tie action until breakage. Fiber breakage and kinking in each ply contributed to the bearing failure. Strain localization and redistribution were observed using DIC.