Fracture Mode Transition Research Articles

Stochastic Extension of Nonlocal Macro–Mesoscale Consistent Damage Model for Fracture Behaviors of Concrete Materials

The nonlinearity and randomness in composite materials such as concrete present challenges regarding the safety analysis and reliability-based design of structures. Based on two-scale damage evolution and physically based geometry–energy conversion, the nonlocal macro–mesoscale consistent damage model (NMMD) shows a unique capability in dealing with the nonlinearity of crack evolution. In this paper, a stochastic extension of the NMMD model is proposed to analyze the stochastic fracture behaviors of concrete materials. The extended model uses the stochastic harmonic function (second kind) to represent the spatial variability in concrete properties and thus to investigate the influence of inhomogeneity in the cracking process. Numerical examples of three-point bending beams without defects and with initial cracks of various sizes demonstrate that the stochastic NMMD model is capable of not only capturing uncertain fluctuations in peak load but also simulating the random walk of the crack path with the instantaneous transition of fracture modes, as observed in experiments. In addition, the effectiveness of the stochastic NMMD model with only a single random field (i.e., Young’s modulus) also contradicts the conventional assertion that stochastic simulations of quasi-brittle fracture should contain at least two mechanical properties with spatial randomness. Finally, the investigation of fracture energy with stochastic fluctuations reveals that randomness resulting from heterogeneity can statistically improve the fracture toughness of concrete materials to some extent.

Microstructure and mechanical properties of aluminum alloy laser welded joint assisted by alternating magnetic field

Magnetic field-assisted laser welding is an effective method to improve the quality of laser-welded joints. In this study, laser welding was conducted on a 2 mm thick sheet of 6061-T6 aluminum alloy, with the assistance of an alternating magnetic field oriented perpendicular to the surface of the sheet. The effects of the alternating magnetic field on the macrostructure, molten pool flow, porosity, grain morphology, and microhardness of the weld seam were analyzed. The results indicate that applying the alternating magnetic field results in more uniform and finer fish scale patterns on the upper surface of the weld. The porosity of the weld is significantly reduced. The Lorentz force generated by the alternating magnetic field suppresses liquid metal flow from the center to the edges of the molten pool, thereby hindering the heat flow and transfer within the pool. This concentration of heat in the lower part of the molten pool increases the size of equiaxed grains at the weld center and promotes the formation of more branches in the columnar grains near the fusion line. Some columnar grains in the columnar grain zone transform into equiaxed grains. Moreover, the microhardness distribution of the weld becomes more uniform, and the hardness in the heat-affected zone increases. Tensile tests revealed that all samples fractured within the weld seam, with the tensile strength of the welded joints increasing by 12.7%. The fracture mode transitions from a mixed ductile-brittle fracture to a purely ductile fracture.

Study on the room temperature compression deformation mechanism and microstructural evolution of Mg-Gd-Y-Zr alloy

This study explores the dynamic impact deformation mechanisms of Mg-Gd-Y-Zr alloys, specifically focusing on the influence of varying Gd content. Using metallographic observation, SEM, EDS, XRD, EBSD, and TEM, along with hardness and room-temperature compression tests, the research investigates the effects of Gd content on the microstructure, mechanical properties, and deformation behaviors of as-cast Mg-(x)Gd-3Y-0.5Zr (x = 6.5/7.5/8.5) alloys.The results show that increasing Gd content reduces grain size and increases the volume fraction of the non-equilibrium eutectic phase Mg24(Gd,Y)5, though with smaller phase dimensions. These alloys exhibit excellent compressive properties at room temperature, with the highest compression deformation rate of 27.8 % observed at 6.5 % Gd and the maximum compressive strength of 401 MPa recorded at 8.5 % Gd, surpassing some high-Gd-content cast and extruded alloys.At lower Gd content, basal slip and tensile twinning are the primary deformation mechanisms. As Gd content increases, these mechanisms evolve to include prismatic slip and compressive twinning. The fracture mode transitions from predominantly ductile to a combination of ductile and brittle features, with an increase in brittle cleavage at higher Gd levels.

Empirical Characterization and Modeling of Cohesive – to – Adhesive Shear Fracture Mode Transition due to Increased Adhesive Layer Thicknesses of Fiber Reinforced Composite Single – Lap Joints

Empirical Characterization and Modeling of Cohesive – to – Adhesive Shear Fracture Mode Transition due to Increased Adhesive Layer Thicknesses of Fiber Reinforced Composite Single – Lap Joints

Prediction of Residual Life of In-Service P91 Steel Joints Based on Fracture Behavior.

P91 steel and P91 steel joints experience performance degradation after serving for 30,000 h in working conditions. To clarify the damage and failure behavior and remaining life of the joints during subsequent service, further creep testing was conducted on the welded joints of P91 steel that had been in service for 30,000 h at three temperatures: 550 °C, 575 °C, and 600 °C. The fracture surface and the cross-section damage behavior were characterized by SEM and EBSD methods. The results show that there are two types of fracture modes in the joints at different temperatures: ductile cracking occurring at the BM, and type IV cracking occurring in the FGHAZ. The threshold stress for fracture mode transition decreases with an increase in working temperature. Type IV cracking near the HAZ is the main reason for the premature failure of joints during service. And based on the fracture mode, the dual-constant L-M method was proposed to predict the strength of in-service joint materials. The testing data are discussed and classified based on the fracture mode in this method, which has high accuracy and can prevent the premature failure of joints.

Research on active load reducing optimization strategy for 6061Al low cycle fatigue cropping process based on crack propagation mode transformation

Low cycle fatigue cropping technology is a new type of cropping technology with advantages such as no chip waste and low load need. Numerous studies have shown that increasing the fatigue frequency or increasing the displacement load can improve the cropping efficiency, but at the same time, it will reduce the quality of the cross-section and cannot achieve a balance between high efficiency and high quality of cross-section. In response to this issue, this paper found the phenomenon of transition of fracture modes (from fatigue mode to tensile fracture mode) of 6061Al material in LCFC process, and proposed the Active Load Reducing Optimization Strategy for 6061Al in LCFC, which achieves a significant improvement in quality of cross-section with a slight loss of cropping efficiency. Firstly, this paper studied the crack fracture mechanism of 6061Al bar under different displacement loads in the LCFC process. It was found that the transition of crack propagation mode in 6061Al- LCFC process was the main reason for the increase in cross-section roughness. The crack propagation mode changed from fatigue propagation to tensile fracture propagation during the LCFC process, and the roughness of the area significantly increased under the tensile fracture propagation mode. Further research has found that the fundamental reason for the contradiction between the cropping efficiency and section quality of 6061Al is the change in time of crack propagation mode transition and tensile fracture zone area under different displacement loads. Finally, the LCFC process was modeled in a time dimension using acoustic emission(AE) technology, and it was divided into three stages according to the AE signals and the fracture mechanism. As a result, an active load reducing optimization strategy for LCFC process was developed to delay the occurrence of tensile fracture propagation modes. Experiments have shown that compared to the traditional LCFC cropping strategy using constant displacement loads, the active load reducing strategy proposed in this paper can reduce the proportion of tensile fracture area, achieve a significant improvement in quality of cross-section with a slight loss of cropping efficiency, thus achieving a balance between efficiency and section quality to some extent. At the same time, an LCFC process section quality efficiency evaluation index with dual weights of efficiency and section quality has been proposed, which can assist in selecting LCFC active load reducing strategy parameters with consideration of efficiency and section quality weights.

Notched Tensile Fracture of a Fe-15Mn-0.6C-2Al Twinning Induced Plasticity Steel at Room Temperature

The tensile fracture behavior of an Al-bearing TWIP steel was investigated by conducting a series of tensile tests on smooth and notched specimens with different notch geometries, focusing on the effects of evolution of the stress triaxiality and the effective strain during deformation. The flow curve and digital image correlation (DIC) analysis evidenced suppression of dynamic strain aging due to Al addition, and therefore, the effects of local inhomogeneous deformation associated with Portevin-Le Chatelier (PLC) band on fracture could be excluded. The smooth specimen fractured with negligible necking despite the absence of PLC bands. As a result, the effective strain was uniform through the gage section and the stress triaxiality (<i>η</i>) of ~0.33 was nearly unchanged over the entire cross-section up to the maximum load. This led to the fracture surface of the smooth specimen being entirely covered with fine equiaxed dimples. For notched specimens, the fracture strain was drastically reduced with decreasing notch radius, indicating the high notch susceptibility of the steel. The effective strain of the notched specimens was the highest at the edge of the notch root, regardless of the notch radius, so cracks first developed at the surface of the notch root. Although the <i>η</i> at the center of the notched specimens (0.40~0.48 depending on the notch radius) was higher than that of the smooth one, the center of the fracture surface of all notched specimens exhibited dimple features that were very similar to the smooth one, even in size. In contrast, in spite of the same <i>η</i> of ~0.33, fractography at the edge of the notched specimens revealed a fracture mode transition from dimple fracture to void sheet fracture to quasi-cleavage fracture as the notch radius decreased. The present results were rationalized in terms of the local evolution of stress triaxiality and effective strain during deformation, which were analyzed using the finite elemental method and DIC technique. It can be said that the fracture mode of TWIP steel, showing limited necking, was more influenced by the distribution and/or gradient of stress traiaxiality and effective strain rather than their local absolute values - that is, the severer their gradient is, the easier the quasi-cleavage fracture occurs.

The Influence of Aging Precipitates on the Mechanical Properties of Al–Li Alloys and Microstructural Analysis

In this work, the evolution of mechanical properties of binary Al–Li alloys with four approximately equal gradient Li contents (0.91–3.98 wt.%) under aging conditions is thoroughly investigated. The alloys undergo aging treatments at 175 °C for x hours (x = 0–120 h), and the peak-aged times of the four alloys are 6 h, 12 h, 48 h and 48 h, respectively, as the Li concentration increases. Both in the solution-treated and peak-aged states, the elastic modulus of binary Al–Li alloys exhibits an approximately linear increase with increasing Li content, consistent with trends predicted by density functional theory (DFT) calculations. Due to the presence of Al3Li precipitates, the modulus of higher-Li-concentration alloys in the peak-aged state increases by approximately 1.4–2.5% compared with that of alloys in the solution-treated state. Additionally, the study finds that increasing Li content significantly enhances the tensile strength and yield strength of the alloy but decreases its ductility, leading to a transition in fracture mode from ductile to brittle, as evidenced by a microscopic analysis of fracture surfaces. Under peak-aged (175 °C/48 h), the alloy with the highest Li content exhibits the maximum tensile strength of 341 MPa and a yield strength of 296 MPa, while its elongation is the lowest at 2.1%. These findings contribute to a deeper understanding of the effects of aging precipitates on the mechanical properties of Al–Li alloys, providing fundamental guidance for the design of future generations of Al–Li alloys.

The low-cycle fatigue behavior and an entropy-based life prediction model for Nickel-based single crystal superalloy across an extensive temperature range

Nickel-based single-crystal superalloys (Ni-SX) are prominently utilized in the fabrication of turbine blade materials for advanced aero-engines, owing to their commendable material characteristics. This paper delves into the low cycle fatigue (LCF) characteristics of a second-generation Nickel-based single-crystal superalloy across a temperature spectrum ranging from room temperature to 1000 °C. During this procedure, there is an escalation in the trend towards deformation homogenization, leading to a transition in fracture mode from shear fracture to normal fracture. A novel approach is introduced in the form of an entropy-based fatigue life prediction model, grounded in the correlation between cumulative plastic strain and entropy increase rate. Through a comparative examination with experimental data, the model demonstrates proficiency in precisely forecasting the fatigue life of Ni-SX under diverse strain amplitudes and temperature conditions.

A novel grain growth algorithm for grain-based models for investigating the complex behavior of crystalline rock

The mineralogical composition and microstructure of crystalline rock affect its mechanical properties. However, it is challenging to analyze and quantify the associated mechanisms using experimental methods. A potential solution to this problem is to apply microscopic simulation methods, such as a combination of the discrete element method and grain-based model (GBM). A prerequisite for microscopic simulations is to accurately reproduce the microscopic features, especially the interactions between grains. Inspired by the crystallization of polycrystalline rocks, a novel grain growth algorithm that constructs a GBM by simulating the sequential crystallization process is proposed in this paper. The results of comprehensive analyses show that the proposed modeling method can accurately reproduce the mineralogical compositions, euhedral-to-anhedral morphology transitions, and grain size distributions during different crystallization processes. By accurately reproducing the interlocking structure between grains, the proposed method can simulate typical mechanical behaviors, such as the nonlinear strength envelope, uniaxial compressive strength-to-tensile strength ratio, and bimodularity, which are consistent with the experimental findings. The effectiveness of this method in modeling porphyritic structures and grain-scale anisotropic textures is demonstrated, and the microscopic mechanism of fracture mode transition associated with the difference in grain structures is discussed.

Orthotropic mechanical properties of PLA materials fabricated by fused deposition modeling

Polylactic Acid (PLA) sample manufactured by fused deposition modeling (FDM) technique is typically assumed to be transversely isotropic without a thorough examination of its orthotropy in three-dimensional space. This study investigated the mechanical orthotropy of PLA samples with two air gap levels (0 mm and -0.05 mm) and various loading directions. Tensile strength and elastic modulus were experimentally measured and the Hill48 yield model and orthotropic elastic model were calibrated. Results revealed that the anisotropy induced by interlayer bond was more pronounced than that within layer. Introducing a -0.05 mm air gap remarkably reduced voids in printed samples, enhancing the stiffness and strength of tensile samples. It also delayed the transition of fracture modes in intra-layer samples as the filament angle increased from 0° to 90°, which shifted from filament breakage to combined fracture mode and subsequently to interface failure. Despite these improvements, the inherent anisotropy of FDM printed PLA materials remained due to the oriented molecular chains and insufficient chain diffusion. The study emphasizes the importance of orthotropic mechanical models, demonstrating their reliability through calibration with acceptable accuracy.

Micro-mechanisms of the ductile-to-brittle transition in hydrogenated zirconium alloys: A review and a comparison analysis of experimental data and theoretical approaches

The primary objective of this article is to gather comprehensive experimental and theoretical data on the fracture process of hydrogenated zirconium alloys at micro- and nano- levels and conduct an extensive analysis to identify consensus statements and any potential contradictions. The article focuses on the physical mechanisms that contribute to the ductile-to-brittle transition in fracture mode and examines published hypothesis that explain these mechanisms. The manuscript contains a comprehensive list of published experimental studies on the mechanical properties of hydrogenated zirconium alloys. This study will be useful for developing and verifying models and for planning of experimental studies and analyzing their results.

Investigation into hydrogen assisted fracture in Nickel oligocrystals

This study investigates the hydrogen embrittlement (HE) behavior of Nickel-201 alloy using the oligocrystal approach. To comprehend the influence of microstructure toward HE, various types of tensile oligocrystals (True-oligocrystals, Quasi-oligocrystals, Identical-oligocrystals, and Bi-crystal type oligocrystals) with diverse microstructure (in terms of Schmid factor distribution and grain boundary types) are generated using a combination of heat treatment and slicing method. The electron backscatter diffraction (EBSD) analysis is used to validate the development of the desired tensile oligocrystal samples. Identical oligocrystal samples established the transition in fracture mode from ductile transgranular (TG) to brittle intergranular (IG), solely driven by hydrogen uptake. Post-tensile deformation analysis validated the hydrogen-induced IG fracture initiation and propagation along the random high-angle grain boundaries (RHAGBs) only. Bi-crystal type oligocrystals with low angle grain boundaries (LAGBs) and coincident-site lattice (CSL) Σ3 grain boundaries exhibited resistance to hydrogen-induced intergranular fracture, thus establishing the ‘special’ nature of these grain boundaries against the HE under current testing conditions.

Shale brittleness evaluation under high temperature and high confining stress based on energy evolution

Deep and ultra-deep shale gas reservoirs are crucial targets for future natural gas development. Extensive research has shown the shale brittleness is closely associated with the hydraulic fracture network quality. However, the shale brittleness may be altered in deep reservoirs due to the high temperature and high geo-stress. At present, commonly used shale brittleness evaluation methods cannot distinguish the differences in energy evolution caused by different mineral components in shale rock. In order to distinguish this difference, this study innovatively proposes a shale brittleness evaluation method that considers mineral composition based on energy evolution. A high-temperature triaxial compression experiment was carried out on the Longmaxi Formation shale, its fracture mode was analyzed, and the brittleness of the shale was evaluated based on this innovative method. The results indicate that with increasing confining stress, the shale fracture mode transitions from brittle tensile-shear multi-crack penetrating fracture to brittle-plastic shear single-crack fracture, and the brittleness of shale shows a decreasing trend. Under low confining stress, the shale brittleness decreases with temperature. Under high confining stress, temperature is the non-main controlling factor of shale brittleness. This study provides valuable guidance for the design and optimization of hydraulic fracturing in deep shale reservoirs.

Dynamic mechanical response and damage constitutive model of end-jointed rock bridge with different water content states under impact load

In rock slope engineering, the dynamic mechanical behavior of rocks is significantly influenced by the length of rock bridges and their moisture content. This study explored the dynamic characteristics of defective rocks under impact loads through dynamic impact tests on specimens varying in rock bridge lengths and moisture states, conducted using a Split Hopkinson Pressure Bar (SHPB). The experimental results revealed that both moisture state and rock bridge length markedly affect the dynamic compressive strength and elastic modulus. Additionally, there is a significant correlation between the energy dissipation density and the specimen's moisture state and rock bridge length. The failure process, captured via a high-speed camera, exhibited a transition in fracture mode from predominantly tensile to tensile-shear failure with increasing rock bridge length. Moreover, an enhanced ZWT model was developed and validated for the dynamic damage constitutive model of defective rocks. This model, incorporating four parameters, precisely characterizes the stress–strain relationship of defective rocks under high strain rates and effectively demonstrates the dynamic response of rocks with varying rock bridge lengths and moisture states. The findings of this study are vital for advancing the understanding of rock dynamics in varying conditions and offer significant insights for geological and civil engineering applications, particularly in the design and assessment of rock structure stability in slopes.

Improving Weldability of Press Hardened Steel Through Combining Stepped Current Pulse and Magnetically Assisted Resistance Spot Welding Process

Abstract Press-hardened steel (PHS), characterized by its extremely high strength, has wide applications in vehicle body manufacturing as an innovative lightweight material. Nevertheless, the poor weldability of PHS results in poor weld toughness and a high risk of interfacial fracture (IF), posing challenges to the resistance spot welding (RSW) process. Introducing an external magnetic field in the welding process to perform electromagnetic stirring (EMS), the magnetically assisted RSW (MA-RSW) process has been proven an effective method to improve the weld toughness of high-strength steel, but it may increase the risk of expulsion. In response to these challenges, this study introduces a new process called SPMA-RSW to improve the weldability of PHS by combining MA-RSW and the stepped-current pulses (SP) technique, which can enlarge the weld lobe. Nugget appearance, microstructure, microhardness, and mechanical properties were systematically investigated by comparing traditional RSW, MA-RSW, SP-RSW, and SPMA-RSW. The result showed that the SPMA-RSW process would significantly increase the nugget size, inhibit the shrinkage voids, finer the grain size of PHS welds, and harden the nugget region. This increased the lap-shear strength and changed the fracture mode from brittle IF mode to ductile plug fracture (PF) mode at the same heat input. Specifically, the peak load and energy absorption were increased by 32.3% and 84.2%, respectively. Then, an analytical model was developed to reveal the mechanism of the effect of EMS on the fracture mode transition and was verified by experiment. This work can help improve the weld quality and thermal efficiency of the RSW process for PHS.

Enhancing mechanical properties of selectively laser sintered SiC/Si composites printed using electrostatic spraying microspheres with fine particles

The SiC/Si composites were prepared via selective laser sintering (SLS) combined with reactive melt infiltration (RMI) of liquid Si, using fine SiC particles with original particle sizes of 0.05, 0.8 and 5 μm. A novel electrostatic spraying combined with phase inversion (ES-PI) method was developed to assemble SiC particles into spherical powders (40–60 μm in diameter) before SLS, enabling SiC with excellent flowability. Commercial coarse SiC microparticles (∼40 μm) were also adopted to prepare the SiC/Si reference composite for comparison. Then the effects of the fine original particle sizes of SiC on the microstructures, as well as mechanical performance of composites were studied. Compared to commercial SiC microparticles, the ES-PI SiC microspheres show superior sphericity and fluidity but a relatively high porosity. However, the pores in ES-PI SiC microspheres, which are potentially detrimental to mechanical properties of composites, will be totally filled and eliminated in the SiC/Si composites after RMI. The mechanical performance of the SiC/Si composites printed using the fine nano (0.05 μm) and submicron (0.8 μm) original particles was effectively improved than the reference composite. When printed using the ES-PI SiC microspheres with 0.05 μm original particles, the flexural strength of the SiC/Si composite was enhanced by 25 %. This is attributed to the cracks deflection as well as the fracture mode transition from transgranular to intergranular rupture by the use of nano- or submicro-sized original SiC particles. This work provides an effective solution for preparing high strength SiC/Si composites with fine nano- or submirco particle sizes for space-based lightweight optical mirror using SLS.

Fracture mode transition from intergranular to transgranular in (TiZrNbTaCr)C: The grain boundary purification effect of Cr carbide

(TiZrNbTaCr)C high-entropy carbide ceramics with different Cr content are fabricated by hot-pressing and the mechanical properties are tested. With increasing Cr content, the fracture mode changed from intergranular to transgranular. Nanoindentation tests indicated that this transition is ascribed to the enhancement of grain boundary strength and atom probe tomography (APT) analysis confirmed indeed different grain boundary impurity concentration ascribed to a purification effect of Cr carbide. Besides, the mismatch degree between the atoms at and in the vicinity of grain boundaries as well as the grain size may also impact grain boundary strength. The fracture toughness presents a decline tendency with increasing Cr content, and its relationship with fracture mode transition is discussed.

Influence of temperature on deformation and damage mechanisms of wire + arc additively manufactured 2219 aluminum alloy

This work investigates the deformation and damage mechanisms of wire + arc additive manufacturing (WAAM) 2219 aluminum alloy over a broad temperature range of 77 K to 523 K. It is found that the strength and work hardening rate increase significantly with decreasing the temperature from 523 K to 77 K, and the fracture mode transitions from transgranular fracture mode to a mixture of intergranular and transgranular fracture ones. The large elongations to fracture are very similar for the specimens tested at 77 K and 523 K. This is mainly attributed to higher uniform elongation before necking at 77 K and higher post-necking elongation at 523 K. The cracking of α-Al + θ (Al2Cu) eutectics is the primary mechanism of micro-void nucleation, independent of the test temperature. The nucleated micro-voids, along with larger gas pore defects introduced by WAAM, extend along the tensile direction. In addition, as the temperature increases from 77 K to 523 K, the fracture mechanism transitions from high strain localization to extensive necking, leading to higher dislocation density, more grain fragmentation and micro-void nucleation, and more significant grain elongation and void growth. True stress and strain responses over the studied temperature range (77 ∼ 523 K) and strain rate range (0.0001 ∼ 0.01 s−1) are well predicted using an improved Arrhenius-type constitutive model, by considering the activation energy of deformation as a function of temperature.

Temperature-dependent oxidation kinetics and mechanical properties degradation of Cf/ZrB2-SiC composites

The oxidation kinetics and microstructures evolution of Cf/ZrB2-SiC composites are investigated by experimental characterizations. An empirical model containing multi-reaction systems is further established for predicting the specimen mass evolution during isothermal oxidantion. Based on the morphological observations and in-situ tensile responses, three oxidation mechanisms of carbon phase controlled by reaction and diffusion kinetic are categorized as uniform, non-uniform and superficial oxidation. The relationship between fracture modes and internal fibers microstructures indicates that the structural origin of the fracture mode transition is the toughening mechanism transition of fibers on the ceramics matrix induced by oxidative damage.