Phase Field Modeling Of Fracture Research Articles

A phase-field gradient-based energy split for the modeling of brittle fracture under load reversal

In the phase-field modeling of fracture, the search for a physically reasonable and computationally feasible criterion to split the elastic energy density into fractions that may or may not contribute to crack propagation has been the subject of many recent studies. Within this context, we propose an energy split – or energy decomposition – aimed at accurately representing the evolution of a crack under load reversal. To this purpose, two key assumptions are made. First, the damage gradient direction is interpreted as being representative of the normal-to-crack direction, as already assumed in previous works in the literature. The second assumption consists of considering the sign of the projection of the stress tensor onto the damage gradient direction at a point as an indicator of whether this point should behave as an opening or as a closing crack. We associate the latter case (crack closing) to both (a) a complete recovery of elastic energy density of the intact material (i.e., perfectly rough crack surfaces) and (b) a zero crack driving force at that point. The first case (crack opening) is treated classically as a damageable material point at which damage can increase. The implementation of the proposed approach turns out to be remarkably simple and computationally robust. For the evaluation of the displacements and damage gradients at nodes, the classical Z2 technique is used, and a new effective and computationally convenient iterative strategy is implemented to guarantee convergence of the staggered scheme. Four examples are presented in order to assess the suitability of the present model by using both AT1 and AT2 regularization models. Results show the desired effect of limiting crack propagation to prevailing tensile states, as well as of recovering the initial intact stiffness upon load reversal, even when two of the most common energy splits fail.

A phase-field length scale insensitive mode-dependent fracture model for brittle failure

This article presents a consistent phase-field length scale insensitive mode-dependent fracture model for brittle failure by proposing mode-factor dependent degradation functions that incorporate the effect of two additional fracture parameters, namely the mode-II critical energy release rate and mode-II fracture strength, on the overall mechanical response. Using the proposed mode-factor dependent degradation functions and employing a recently proposed modified strain decomposition scheme, we provide analytical expressions for the mode-I and mode-II fracture strengths corresponding to the mode-dependent parts of the elastic energy. Adopting a modified Benzeggagh–Kenane (B–K) criteria, we propose mode-dependent driving forces by deriving expressions for the critical energy release rate corresponding to individual fracture modes. The proposed model provides a consistent coupling between the different fracture modes and can thus predict fracture for all possible mode-mixity ratios. A parametric study is carried out to unravel the effect of mixed-mode fracture parameters on the mechanical response of isotropic materials by considering a few representative numerical examples. The numerical results from the proposed model show an excellent agreement with experimental results reported in the literature.

Mechanical Failure of Core-Shell Cathode Particles: The Effects of Concentration-Dependent Material Properties and Phase Field Fracture Modelling

The use of core-shell cathode particles in lithium-ion batteries is an attractive approach to enhancing energy density whilst retaining lifetime, through reducing undesired reactions at the electrode-electrolyte interface and limiting the volume change of the electrode particles. However, mechanical failure through the fracture and debonding of the core-shell interface is a major challenge. In this work, we employ a coupled finite-element model to predict and mitigate the mechanical failure of core-shell cathode structures, taking as example a particle of NMC811 (core) coated with NMC111 (shell). In particular, we focus on two aspects:The first one involves the assumptions of material properties as inputs of the model. The material properties are often considered constant by battery modelling researchers, yet these parameters can vary significantly during charge/discharge. For example, experiments have unveiled a three-orders-of-magnitude drop in the diffusion coefficient of NMC materials during discharge [1]. Here, we incorporate material properties obtained from experimental data, including concentration-dependent diffusion coefficient obtained from GITT measurement and partial molar volume derived from in situ X-ray diffraction data. Our results indicate that when assuming a concentration-dependent partial molar volume, the maximum values of tensile hoop stress in the shell are nearly three times lower than those predicted with constant average properties, diminishing the likelihood of fracture.When accounting for concentration-dependent diffusion coefficient, large concentration gradient is observed near the outer surface of the core due to reduced lithium mobility at high states of lithiation, hindering full electrode capacity utilisation. The significant concentration gradient and capacity underutilisation align with direct observations from experiments [2]. Notably, these phenomena cannot be captured in modelling if assuming constant diffusion coefficient. These findings offer new perspectives on the performance and design of core-shell electrode particles. Safe design maps in terms of core size and shell thickness to mitigate fracture and debonding are obtained.The second focus of this work is the utilisation of phase field fracture model in predicting cracking behaviours within the core-shell particle. Phase field modelling provides a continuous representation of cracks, enabling the tracking of complex cracking patterns [3]. We predict cracking behaviors caused by volume changes during charge/discharge, as well as inaccessible capacity and newly created active surface area caused by cracking. Our multiphyics model can hopefully act as a catalyst, accelerating the development process of the core-shell structured cathode particles and shortening the time to market of advanced batteries with extended lifetime.

A computational approach for phase-field model of quasi-brittle fracture under dynamic loading

AbstractA computational model is formulated for studying dynamic crack propagation in quasi-brittle materials exposed to time-dependent loading conditions. Under such conditions, inertial effects of structural components play an important role in modelling crack propagation problems. The computational model is proposed within the theory of regularised cracks which uses a damage-like internal variable. Here, fracture considers phase-field damage which gives rise to a material degradation in a narrow material strip defining the regularised crack. Based on the energy formulation using the Lagrangian of the system, the proposed computational approach introduces a staggered scheme adopted to solve the coupled system and providing it in a variational form within the time stepping procedure. The numerical data are obtained by quadratic programming algorithms implemented together with a finite element code.

Verification of strain energy splits of phase field fracture model using Westergaard’s problem under mixed-mode loading

One challenge in verifying strain energy splits in phase field fracture models is the lack of reference problems with exact solutions in mixed-mode loading that could serve as benchmark problems. In this work, different strain energy splits used in the variational phase field model have been applied to the classical Westergaard’s problem. In contrast to other benchmark problems used in the literature, the proposed problem not only includes the singular term as a boundary condition but also implicitly considers all terms. To the authors’ knowledge, this is the first time in the literature that this reference problem has been used to rigorously verify the accuracy of different energy splits of the phase field model. Several critical factors such as the pre-crack definition, mesh size, mixed mode ratio and the length scale parameter have been analysed. A good correlation between the numerical estimations and the analytical predictions was found for some pre-crack definition approaches under mode I. However, we demonstrated that the compatible regularisation length scale and mesh size are significantly lower under mode II loading (i.e., when the crack kinks) than under mode I.

Anisotropic damage evolution in solid fractures: A novel phase field approach with multiple failure criteria and directional-dependent structural tensor

This study proposes a novel phase-field fracture model based on unified phase field theory, aiming to overcome current limitations in simulating material complex fracture behaviors. Through this model, analytical solutions for two-dimensional bars subjected to tensile or compressive stresses are provided, enabling the coupling of multiple failure criteria and further proficient simulation of mode-I, mode-II, and mixed mode-I/II fractures, effectively addressing challenges faced in modelling materials with different or complex failure modes under various loading conditions. Furthermore, to account for the strong anisotropic failure behavior of materials, a novel directional-dependent structural tensor is proposed. The tensor correlates fracture energy with crack surface orientation, facilitating precise characterization of material damage evolution with multiple potential crack orientations. This tensor ensures the consistency of phase-field fracture evolution with predefined fracture patterns. The effectiveness of the proposed model is validated through case studies, emphasizing its robustness and superior predictive capability in capturing fracture behavior under various conditions. This research provides a more accurate and universally applicable approach for simulating material failure, particularly for complex or multiple failure mode material failure simulations.

Phase field modelling of elastic-plastic fatigue fracture of oil and gas pipeline

This paper established a fatigue fracture phase-field model (PFM) to evaluate fatigue damage evolution and crack propagation in oil and gas pipeline. To address inaccuracies in damage evolution, a threshold of the elastic-plastic fracture energy was introduced in the proposed PFM. Using the finite element method, the PFM was applied to simulate fatigue crack growth. Results from compact tension (CT) specimen of the X56 gas pipeline steel demonstrated that the da/dN-ΔK curve from the current PFM, accounting for plasticity, aligned more closely with experimental results than the elastic PFM. The fatigue crack propagation and fatigue life of the X80 gas pipeline with different defects of the same depth were also analyzed. The results indicated that triangular defects significantly impacted the fatigue life of the X80 gas pipeline. Finally, a model of X60 pipeline with various initial defects was developed to validate the effectiveness of the proposed PFM for full-scale pipeline fatigue fracture by comparing it to experimental a-N curves. The simulation results indicated that the distance and angle between two initial defects in the pipeline significantly influenced the propagation of fatigue cracks and the pipeline’s service life. These findings of this paper can serve as a reference for estimating the service life of gas and oil pipelines.

Calibration and validation of a phase-field model of brittle fracture within the damage mechanics challenge

In the context of the Damage Mechanics Challenge, we adopt a phase-field model of brittle fracture to blindly predict the behavior up to failure of a notched three-point-bending specimen loaded under mixed-mode conditions. The beam is additively manufactured using a geo-architected gypsum based on the combination of bassanite and a water-based binder. The calibration of the material parameters involved in the model is based on a set of available independent experimental tests and on a two-stage procedure. In the first stage an estimate of most of the elastic parameters is obtained, whereas the remaining parameters are optimized in the second stage to minimize the discrepancy between the numerical predictions and a set of experimental results on notched three-point-bending beams. The good agreement between numerical predictions and experimental results in terms of load–displacement curves and crack paths demonstrates the predictive ability of the model and the reliability of the calibration procedure.

Smoothed point interpolation methods for phase-field modelling of pressurised fracture

The problem of hydraulic fracturing is of great relevance to various areas and is characterised by the occurrence of complex crack patterns with bifurcations and branches. For this reason, an interesting approach is the modelling of hydraulic fracture using a phase-field model. In addition to the discretisation using the Finite Element Method (FEM), some works have already explored the discretisation of the phase-field model with meshfree methods, including the Smoothed Point Interpolation Methods (SPIM) family. Seeking to take advantage of the good convergence results of SPIM for phase-field modelling of brittle fractures, this paper proposes the use of SPIM for phase-field modelling of pressurised fractures. In order to limit the computational cost, a prescribed SPIM-FEM coupling is employed, with the purpose of concentrating the meshless discretisation only in the regions of expected crack propagation. The model is characterised by a constant internal pressure load along the fracture that is applied indirectly from the formulation of the phase-field model. A series of numerical simulations is presented. The aim is to evaluate the proposed model, verify the results and point out characteristics of the phase-field model with internal pressure.

What is the physical origin of the gradient flow structure of variational fracture models?

We investigate a physical characterization of the gradient flow structure of variational fracture models for brittle materials: a Griffith-type fracture model and an irreversible fracture phase field model. We derive the Griffith-type fracture model by assuming that the fracture energy in Griffith's theory is an increasing function of the crack tip velocity. Such a velocity dependence of the fracture energy is typically observed in polymers. We also prove an energy dissipation identity of the Griffith-type fracture model, in other words, its gradient flow structure. On the other hand, the irreversible fracture phase field model is derived as a unidirectional gradient flow of a regularized total energy. We have considered the time relaxation parameter a mathematical approximation parameter, which we should choose as small as possible. In this research, however, we reveal the physical origin of the gradient flow structure of the fracture phase field model (F-PFM) and show that the small time relaxation parameter is characterized as the rate of velocity dependence of the fracture energy. It is verified by comparing the energy dissipation properties of those two models and by analysing a travelling wave solution of the irreversible F-PFM. This article is part of the theme issue 'Non-smooth variational problems with applications in mechanics'.

Cracking mechanism of CMAS-corroded thermal barrier coatings based on a coupled thermo-chemo-mechanically phase-field fracture model

A thermo-chemo-mechanically coupled theoretical framework is proposed to describe the calcium-magnesium-alumina-silicate (CMAS) corrosion process during the cooling process. A phase-field fracture model is developed to investigate the effect of cooling temperature and CMAS concentration on the degree of corrosion reaction, the stress evolution and the crack initiation and propagation. σ11 concentrates in the region beneath the overlay of CMAS and σ22 appears at the interface between top ceramic coating (TC) and bond coating (BC). The higher stress concentration of σ11 and σ22 contribute to the formation of both vertical and transverse cracks. Transverse cracks first emerge at the interface between TC and BC in the edge region, followed by the formation of vertical cracks in the CMAS-coated region. Vertical cracks propagate to the interface and deflect into transverse cracks. The transverse cracks at the interface further propagate and merge, ultimately leading to the coating delamination. The higher initial cooling temperature and CMAS concentration contribute to the accelerated development of vertical cracking and the increase of the quantity and length of transverse and vertical cracks. The model provides a significant advantage in predicting the failure of TBCs during the cooling stage of CMAS corrosion.

Phase-field modeling of thermal shock fracture in functionally graded materials

In this paper, the thermo-elastic fracture problems of functionally graded materials (FGMs) are thoroughly investigated based on a modified phase field model. In this model, the material constants and fracture toughness vary along a specified direction, the thermal conductivity and stiffness constants in the damaged regions are degraded by the phase-field variable, and the crack evolution is driven by the variation of elastic energy induced by the thermo-mechanical loading. Therefore, the temperature, mechanical and damage fields are coupled with each other. The validation of the present approach has been checked by comparing the present results with the analytical, numerical, and experimental results in literature. The examples of thermo-elastic tensile fracture and thermal shock cracking of FGMs are performed to investigate the influence of material heterogeneity and external thermal loading. Furthermore, the experimental phenomenon of crack deflection in FGMs has been captured by the present simulations. The present study provides a guidance for understanding the fracture mechanism, material design and safety assessment of FGM structures in engineering practice.

Mechanical property evaluation of 3D multi-phase cement paste microstructures reconstructed using generative adversarial networks

This study proposes an artificial intelligence based framework for reconstructing the 3D multi-phase cement paste microstructure to evaluate its mechanical properties using simulation. The reconstruction of cement paste microstructures is performed using modified generative adversarial networks (GANs) based on microstructural images from micro-CT. For computational efficiency, 2D microstructures are first reconstructed and then extended to 3D microstructures. The reconstructed microstructures exhibit the same microstructural features as the original microstructures when characterized by probability functions. Mechanical properties such as stiffness and tensile strength are evaluated for the original and reconstructed specimens using a phase-field fracture model, and similar behaviors are observed. The results confirm that the reconstructed virtual microstructures can be used to supplement the real microstructures in evaluating the mechanical properties of 3D multi-phase cement paste. This approach thus provides a critical element of a data-driven approach to correlating its microstructure and properties.

Modelling and simulation of natural hydraulic fracturing applied to experiments on natural sandstone cores

AbstractUnder in-situ conditions, natural hydraulic fractures (NHF) can occur in permeable rock structures as a result of a rapid decrease of pore water accompanied by a local pressure regression. Obviously, these phenomena are of great interest for the geo-engineering community, as for instance in the framework of mining technologies. Compared to induced hydraulic fractures, NHF do not evolve under an increasing pore pressure resulting from pressing a fracking fluid in the underground but occur and evolve under local pore-pressure reductions resulting in tensile stresses in the rock material. The present contribution concerns the question under what quantitative circumstances NHF emerge and evolve. By this means, the novelty of this article results from the combination of numerical investigations based on the Theory of Porous Media with a tailored experimental protocol applied to saturated porous sandstone cylinders. The numerical investigations include both pre-existing and evolving fractures described by use of an embedded phase-field fracture model. Based on this procedure, representative mechanical and hydraulic loading scenarios are simulated that are in line with experimental investigations on low-permeable sandstone cylinders accomplished in the Porous Media Lab of the University of Stuttgart. The values of two parameters, the hydraulic conductivity of the sandstone and the critical energy release rate of the fracture model, have turned out essential for the occurrence of tensile fractures in the sandstone cores, where the latter is quantitatively estimated by a comparison of experimental and numerical results. This parameter can be taken as reference for further studies of in-situ NHF phenomena and experimental results.

A micromagnetic-mechanically coupled phase-field model for fracture and fatigue of magnetostrictive alloys

Magnetostrictive alloys are usually brittle materials with micromagnetic structures. Their structural reliability and durability depend on the complex micromagnetic-mechanical coupling at smaller length scales encompassing the evolution of micromagnetic structures. Herein we propose a micromagnetic-mechanically coupled phase-field model for fracture and fatigue behavior of magnetostrictive alloys with evolution of the micromagnetic structure. The thermodynamically-consistent model is derived from microforce theory, laws of thermodynamics, and Coleman–Noll analysis. The evolution of crack phase-field and magnetization-vector order parameters that are fully coupled is governed by history field dependent Allen–Cahn and Landau–Lifshitz–Gilbert equations, respectively. The model is extended to fatigue by introducing a degradation prefactor for the fracture energy as a function of positive elastic energy. One-dimensional analyses are then presented to anatomize the crack driving forces in terms of fully coupled micromagnetic-mechanical and pure mechanical driving force. We demonstrate the model capabilities by finite-element numerical studies on the micromagnetic domain evolution during the crack propagation and the influence of external magnetic field for type-I, type-II, and three-point bending fracture, as well as for the fracture of a single-edge notched specimen with an elliptical inclusion. The simulation result shows that depending on how micromagnetic domains are switched under micromagnetic-mechanical coupling, the magnetic field can enhance or decrease the critical load. In the presence of inclusion with larger fracture toughness, a crack is found to nucleate in the tri-junction of multi-domain micromagnetic structure owing to the high elastic strain around the tri-junction point. It is further found that a suitable magnetic field promoting magnetization-vector rotation around the crack tip could remarkably improve the fracturing load and fatigue life. The results demonstrate the model promising for the study of micromagnetic-mechanically coupled fracture and fatigue in magnetostrictive alloys.

Phase-field ductile fracture simulations of thermal cracking in additive manufacturing

We present a multiphysics phase-field fracture model for thermo-elasto-plastic solids in the context of finite deformation and apply it to simulate the hot cracking phenomenon during metal additive manufacturing. The model is derived in a thermodynamically consistent manner, with the intercoupling mechanisms among elastoplasticity, phase-field crack and heat transfer comprehensively considered. It involves particularly coupled parameters among these materials physics, e.g. plasticity-dependent degradation function and fracture toughness, damage-dependent yield surface and thermal properties, and temperature-dependent elastoplastic properties and fracture strength. The finite element implementation of the coupled phase-field model is benchmarked with simulation results of a tensile test of an I-shape specimen, encompassing elastoplasticity, hardening, necking, crack initiation and propagation, in contrast to the related experimental results. The validated model is further employed to simulate the multiphysics hot cracking phenomenon in additive manufacturing in the context of both the effective powder-bed model and the powder-resolved model thanks to prior non-isothermal phase-field powder-bed-fusion simulations. Simulation results reveal certain key features of the hot crack and its dependency on process parameters like beam power and scan speed, which are helpful for the fundamental understanding of crack formation mechanisms and process optimization.

A phase-field fracture model in thermo-poro-elastic media with micromechanical strain energy degradation

This work extends the hydro-mechanical phase-field fracture model to non-isothermal conditions with micromechanics based poroelasticity, which degrades Biot’s coefficient not only with the phase-field variable (damage) but also with the energy decomposition scheme. Furthermore, we propose a new approach to update porosity solely determined by the strain change rather than damage evolution as in the existing models. As such, these poroelastic behaviors of Biot’s coefficient and the porosity dictate Biot’s modulus and the thermal expansion coefficient. For numerical implementation, we employ an isotropic diffusion method to stabilize the advection-dominated heat flux and adapt the fixed stress split method to account for the thermal stress. We verify our model against a series of analytical solutions such as Terzaghi’s consolidation, thermal consolidation, and the plane strain hydraulic fracture propagation, known as the KGD fracture. Finally, numerical experiments demonstrate the effectiveness of the stabilization method and intricate thermo-hydro-mechanical interactions during hydraulic fracturing with and without a pre-existing weak interface.

Phase-field modeling of fracture with physics-informed deep learning

We explore the potential of the deep Ritz method to learn complex fracture processes such as quasistatic crack nucleation, propagation, kinking, branching, and coalescence within the unified variational framework of phase-field modeling of brittle fracture. We elucidate the challenges related to the neural-network-based approximation of the energy landscape, and the ability of an optimization approach to reach the correct energy minimum, and we discuss the choices in the construction and training of the neural network which prove to be critical to accurately and efficiently capture all the relevant fracture phenomena. The developed method is applied to several benchmark problems and the results are shown to be in qualitative and quantitative agreement with the finite element solution. The robustness of the approach is tested by using neural networks with different initializations.

Phase Field Fracture Model for Assessing the Load Bearing Capacity of Fractured Glass

The use of glass as structural material has highlighted the need for more reliable numerical approaches to analyze its mechanical behavior, especially in the accidental eventuality of fracture. Modelling the behavior of fractured laminated glass, in fact, is fundamental to assess the Post-Fracture load-bearing capacity. However, this is a highly challenging task because of the many interplaying factors, such as the viscoelastic and thermal-dependent behavior of the interlayer, the presence of a highly complex and variable crack pattern and the interaction among fragments. The objective of the present work is the development and testing of a robust numerical model that can naturally introduce the generated crack pattern into virtual specimens and manage the interaction among many fragments. The phase field fracture model is herein explored, by assigning the damage variable to fit the pre-existing crack pattern. Then, the specimen is loaded letting the phase field managing the fragments interaction. The dependence of the stress tensor with the damage variable is herein defined through the Cleavage-Deviatoric model, since it prevents fully damaged regions from transmitting tensile and shear stresses yet keeping their ability to bear compressive forces. Indeed, this model can asymptotically reproduce unilateral and frictionless contact conditions between the existing crack lips. Preliminary case studies are discussed to check the potentiality of the proposed approach.

Length Scale Insensitive Phase-Field Fracture Methodology for Brittle and Ductile Materials

We present length scale insensitive phase-field fracture models for brittle and ductile fracture to address the deficiencies of widely implemented models which over-estimate crack dissipation. An approach is proposed to attain a regularization length scale insensitive mechanical response, which considers a continuous approximation of a crack boundary with a function of infinite support. This is in contrast to previous approaches to attain a length scale insensitive response which exploited approximations of the crack boundary with functions of finite support. The choice of these functions with finite support creates implementational challenges which are avoided in the presented quasi-brittle and ductile fracture models with infinite support of the phase-field. The capability of these models is demonstrated in several benchmarks with attention given to the sensitivity of the structural response with respect to the choice of regularization length scale. The models are validated against a three-point bending test on a concrete specimen and an in-plane shear test on a steel specimen.