Crack Propagation Research Articles

Machine Learning Approach for LPRE Bearings Remaining Useful Life Estimation Based on Hidden Markov Models and Fatigue Modelling

Ball bearings are one of the most critical components of rotating machines. They ensure shaft support and friction reduction, thus their malfunctioning directly affects the machine’s performance. As a consequence, it is necessary to monitor the health conditions of such a component to avoid major degradations which could permanently damage the entire machine. In this context, HMS (Health Monitoring Systems) and PHM (Prognosis and Health Monitoring) methodologies propose a wide range of algorithms for bearing diagnosis and prognosis. The present article proposes an end-to-end PHM approach for ball bearing RUL (Remaining Useful Life) estimation. The proposed methodology is composed of three main steps: HI (Health Indicator) construction, bearing diagnosis and RUL estimation. The HI is obtained by processing non-stationary vibration data with the MODWPT (Maximum Overlap Discrete Wavelet Packet Transform). After that, a degradation profile is defined and coupled with crack initiation and crack propagation fatigue models. Lastly, a MB-HMM (Hidden Markov Model) is trained to capture the bearing degradation dynamics. This latter model is used to estimate the current degradation state as well as the RUL. The obtained results show good RUL prediction capabilities. In particular, the fatigue models allowed a reduction of the ML (Machine Learning) model size, improving the algorithms training phase.

Intrinsic mechanism of grain size effect and grain boundary misorientation angle effect on crack propagation in martensitic steels

Grain size and grain boundary misorientation angle as two important parameters in the polycrystalline system have a significant influence on the mechanical properties of advanced martensitic steels. A phase field model is used to investigate the intrinsic mechanism of the effects of grain size and grain boundary misorientation angle on the crack propagation process which considers the coupling damage behavior between grains and grain boundaries in martensitic steels by means of the finite element finite method. The transgranular (through grain boundaries) and intergranular (along grain boundaries) failure can be simulated by this model through constructing a grain boundary energy function and using a specific order parameter to track crack propagation in the grain boundary area. This model can directly display the crack propagation path inside the grain (martensite and austenite phases) and grain boundary area with the stress distribution. The preferential cleavage planes in austenite and martensite phases are 111γ and 100α in grains with different orientations, respectively. Moreover, the simulation results show that the crack mainly bifurcates near the trifurcated grain boundary. The crack tip tends to induce transgranular fracture in low-angle grain boundaries and intergranular fracture in high-angle grain boundaries when it reaches the grain boundary area. Consequently, this model will be a powerful tool to investigate the influence of grain size and grain boundary misorientation angle on the mechanical properties of polycrystalline martensitic steels.

Experimental and Numerical Investigation of the Fracture Behavior of Extruded Wood-Plastic Composites under Bending.

The ability of wood-plastic composites (WPCs) to withstand various loads and resist plastic failure is attracting more and more interest due to the global increase in demand for WPCs by over 6 million tons per year. Among the most important and innovative research methods are those based on fracture mechanics-their results enable material designers to optimize the structures of these hybrid polymer composites at the nano, micro and macro levels, and they allow engineers to more accurately evaluate and select functional, sustainable, long-lasting and safe product designs. In this study, standard single-edge notched bending (SENB) tests were used to analyze the fracture toughness of two different extruded WPCs along the longitudinal (L) and transverse (T) directions of extrusion. In addition to their resistance to crack propagation, critical fracture criteria, initial contact stiffness, fracture parameters and fracture surfaces, the mechanical properties of these composites were also investigated. The results showed that WPC-A coded composites withstood higher loads until failure in both directions compared to WPC-B. Despite the larger data spread, both types of composites were more resistant to crack propagation in the T direction. Mode II of crack propagation was clearly visible, while mode III was not as pronounced. The experimental results and the numerical finite element (FE) model developed up to 58% of the maximum load correlated well, and the obtained deformation curves were best approximated using cubic equations (R2 > 0.99). The shear stress zone and its location, as well as the distribution of the equivalent stresses, had a major influence on crack propagation in the fracture process zone (FZP).

Analysis of Fracture Damage Mechanical Properties of Particle Reinforced Polymer Composite Film Based on Micro-macro Finite Element Method

Abstract The particle reinforcement and related effect on fracture damage mechanical properties of polymers have been studied in this paper. Based on the uniaxial tensile test result of particle reinforced PVDF composites, the parameters of macro elastic-plastic finite element model and the micro particle reinforced model are obtained. The effects of boundary conditions, shape and size of damage notch on fracture damage mechanical properties of PVDF composites are studied from macroscopic view. The uniaxial tensile mechanical properties and elastic modulus are increased with notch angle. The damage analysis of the micro model shows that the reinforcement of composite is best when the content of SiO2 is 6%. Debonding between particles and matrix indicates have great effect on crack propagation. The micro-macro finite element model is effective tool to study the damage mechanical properties of particle reinforced polymers.

Accelerated corrosion tests of a contact pair austenitic stainless steel – titanium alloy

The results of accelerated corrosion tests of a pair of austenitic stainless steel — titanium alloy under conditions of elevated temperatures and high concentrations of corrosive agents are presented, conditions for the developing the mechanism of local corrosion being the same. The proposed approach included provoking the appearance of microstress concentrators by three-point loading of test samples with subsequent forced development of local types of corrosion through simultaneous exposure to an increased concentration of corrosive agents and temperatures at a fixed exposure in an autoclave. The results of modeling the corrosion process in a titanium alloy being in contact with stainless steel are assessed proceeding from the data obtained from metallographic studies of the state of surface layers of the metal and the morphology of corrosion products on prepared sections of the surface of templates cut from the samples under study. We considred a pair of steel 08Kh18N10T — titanium alloy VT-5. It is shown that the contact of samples under conditions of accelerated corrosion tests does not lead to a significant development of local types of corrosion of the titanium alloy. On the contrary, analysis of the state of the surface layers of the samples of stainless steel revealed the presence of deep corrosion pits, triggering the intergranular corrosion. In this case, corrosion of austenitic steel, both in the presence and in the absence of contact with titanium, proceeded in three stages: the initiation and fusion of pitting; formation of knife corrosion ulcers; propagation of intergranular cracks into the depth of steel. The proposed methodology of corrosion testing can be used to predict the possible nature of the development of metal corrosion under operating conditions that form local zones of static stresses in structural materials, and for prompt response to extend the design life of the equipment at thermal and nuclear power facilities.

Well-Tailored Norbornene-Based Fluorinated Copolymers toward Modulating Icephobicity and Mechanical Robustness.

Well-tailored construction of icephobic surfaces with mechanical robustness and investigation of the structure-property relationships at the molecular level are highly desirable. Herein, a series of norbornene-based fluorinated polyolefin copolymers (FPOR-x) with varying norbornenyl dodecafluoroheptyl ester (NDFHE) molar fractions (0-100 mol %) were well-designed and fabricated via living ring-opening metathesis polymerization (ROMP) employing NDFHE and norbornenyl pentafluorophenyl ester (NPFPE) as the soft and hard segments, respectively. The mechanical and icephobic properties of the fluorinated copolymers can be regulated by adjusting the soft NDFHE contents. As a result, the well-designed norbornene-based copolymers exhibited a wide range of tunable mechanical properties, including tensile strength ranging from 0.2 to 26.4 MPa, elastic modulus ranging from 0.6 to 593.7 MPa, and breaking elongations ranging from 5718.7% to 3.7%, correlating with the proportion of soft NDFHE content. Furthermore, the synergistic interplay between soft and hard segments, particularly the hardness in the majority and softness in the minority or vice versa, could achieve a significant difference in the local modulus and enhance the propagations of cracks within the three-phase regions (soft regions/hard regions/ice), ultimately leading to a significant reduction in ice shear strength. Notably, FPOR-25% with a tensile strength of 12.0 MPa and an elastic modulus of 227.5 MPa exhibited a remarkably low ice shear strength of 57.7 kPa. This study not only highlights the relationship between the polymer molecular structure and surface icephobic properties but also breaks the limitations of icephobic surfaces with a low modulus.

Atomic force microscopy monitoring of subcritical slow crack growth in soda lime silicate glass

Prediction of brittle fracture in silicate glasses requires a fundamental understanding of slow crack growth rates, far below the critical stress intensity (KIC) of the material. Here, atomic force microscopy (AFM) was used to characterize slow crack propagation in soda lime silicate glasses. Using large-sample AFM systems with specialized tips and scanners, fractures less than 20 nm wide were measured as a function of relative humidity (RH). The results were found to be sensitive to the type of AFM tip used and to the dryness of the surface. Continuous scanning and image capture over several days allowed the determination of the crack tip velocity. The dependance of crack tip velocity on RH was measured by enclosing the sample and AFM head in a humidity-controlled chamber. The crack tip velocity was measured as low 4.0×10-12 m/s at 15 % RH and as high as 3.7×10-10 m/s at 40 % RH. Overall crack growth was smooth during the AFM scan. Additionally, recession of the crack tip was noted as the sample dried, indicating crack tip closure may be occurring. Further studies on alternative compositions will provide details on subcritical fracture processes in a range of different environmental conditions.

Experimental and numerical investigation on crack propagation for a zigzag central cracked Brazilian disk

Experimental and numerical investigation on crack propagation for a zigzag central cracked Brazilian disk

Influence of rolling defects on fatigue crack initiation of leaf spring

ABSTRACT Leaf springs, as vital suspension components in trucks, endure various forces such as torsion, compression, tension and impact, rendering them highly susceptible to fatigue and fracture risks, thereby posing a significant threat to vehicle safety. During the production process of leaf springs, surface decarburisation can easily occur, leading to the formation of numerous surface rolling defects. These defects exert varying influences on the initiation of fatigue crack. This study investigates the influence of various forms of rolling defects caused by decarburisation on fatigue crack initiation in 50CrMnMoNbAT leaf spring through experimental and numerical analysis of fatigue fracture behaviour. The results indicate that fracture locations in the leaf springs are predominantly concentrated approximately 297 mm and 698 mm from the ends. Furthermore, the occurrence of surface decarburisation during the rolling process engenders a significant number of surface rolling defects. Surface defects in leaf springs can be categorised into three forms: Parallel defect, Parcel defect and Occlusal defect. In terms of defect propagation rate, rolling defects on the concave surface are most prone to initiate fatigue cracks, with Occlusal defects exhibiting the highest likelihood of developing internal cracks and the fastest crack propagation rate.

Thermo-mechanical fatigue crack growth in a nickel-based powder metallurgy superalloy

Fatigue crack growth is studied in a nickel-based powder metallurgy (PM) superalloy (FGH4099) subjected to in-phase (IP) and out-of-phase (OP) thermo-mechanical fatigue (TMF), as well as isothermal fatigue (IF) at peak temperature. The crack growth rate and path are evaluated for both coarse grain (CG) and fine grain (FG) FGH4099, especially the effects of phase angle and polycrystalline microstructure. The results show that the TMF crack propagation is mainly transgranular in OP condition; while in IP condition, fatigue crack propagates intergranularly at low ΔK and transforms to transgranular after passing the transition region. The crack propagation resistance for FG microstructure is lower than that for CG microstructure at elevated temperature, as a result of secondary cracks and grain boundary weakening effect. Crystallographic slip controls the crack propagation process, while the twin boundaries (TB) and special grain boundaries also exert a significant influence on crack deflection. The formation of secondary cracks is closely related to local misorientation and crystallographic deformation during TMF crack propagation. The crack deflection in a single grain reveals a competition mechanism between crystallographic slip and grain boundary effect, which explains the lower crack growth rate for OP when compared to IP or IF.

High-temperature high cycle fatigue performance of laser powder bed fusion fabricated Hastelloy X: Study into the microstructure and oxidation effects

High-temperature fatigue properties are critical for laser powder bed fusion (LPBF) fabricated Nickel-based superalloy Hastelloy-X (HX) used in aero engines. In this study, superior high-temperature high-cycle fatigue properties of LPBF HX were achieved. The detailed investigations show that the grain boundary oxidation promoted by the different deformation modes between neighboring grains, despite the reduced oxygen-related damage in the coarser LPBF HX microstructures, are the potential causes for the inter-granular fatigue crack initiation and the subsequent crack coalescence. In the meantime, the crack propagation could be hindered by the refined carbides and annealing twins with Σ3 misorientation (60°/〈111〉) in LPBF HX. Furthermore, the recrystallized grains formed ahead of the crack tip due to the severe deformation within the plastic zone and high testing temperature have different crystallographic orientations, which leads to the crack propagation path changes and increases the fatigue crack propagation resistance.

Toughening of self-reinforced PLA films using PLA nanofiber mats and oriented PLA tapes as interlayers

Self-reinforced poly(lactic acid) composite (SRPLA) offers advantages in terms of convenient recycling due to its mono-material nature, potential biodegradability, and biocompatibility. Moreover, SRPLA has shown the ability to overcome the inherent brittleness of PLA. To deepen our understanding of how different types of reinforcements and process parameters can affect tensile properties, particularly tensile toughness, SRPLA has been prepared based on oriented tapes (ot-SRPLA) as well as nanofiber mats (nf-SRPLA) using a film-stacking and hot-compaction approach. A considerable improvement was observed in tensile strength, modulus, and toughness at the optimum consolidation temperature and time. Specifically, the tensile toughness of nf-SRPLA increased approximately threefold at a very low nanofiber loading of 0.56 wt%, while the toughness of ot-SRPLA more than doubled at a tape mass fraction of 36 wt%. In terms of toughening mechanisms, the presence of the nanofibers slowed down crack propagation through crack branching, deviation, and fiber bridging in nf-SRPLA, whereas the predominant toughening mechanisms were interlayer debonding and tape pull-out for ot-SRPLA.

Correlation between microstructure and fracture mechanism of 960 MPa Grade ultra-high toughness steel

This study investigated the correlation between microstructure and fracture mechanisms in a 960 MPa grade ultra-high toughness high strength low alloy steel produced through controlled rolling and off-line heat treatment. The steel features a low-carbon composition (≤0.1 wt%) and a fine-grained(≤10 μm) bainitic microstructure. Through microstructural characterization and fractographic analysis, extensive quantitative analysis of grain, packet, dimple, and cleavage facet sizes was conducted. Fracture surfaces were examined to identify crack initiation sites. The findings indicate that grain refinement significantly enhances toughness. In fine-grained conditions, bainitic packets that approximate the size of the grains modulate crack propagation pathways. The near-oriented bainite across adjacent grains forms structures comparable to abnormally large grains, crucial for crack nucleation. Moreover, martensite/austenite (M/A) islands, while crucial to the initiation of cracks, require the synergistic interaction with grain boundaries and inclusions to significantly influence fracture initiation. This investigation elucidates the complex interplay between microstructural refinement and fracture mechanisms.

Experimental Study on Coconut Fibre Reinforced Self Compaction Concrete

Self-Compacting Concrete (SCC) has revolutionized the construction industry with its superior flowability, workability, and ability to consolidate under its own weight without the need for mechanical vibration. However, the brittleness and cracking susceptibility of traditional SCC remain significant concerns, especially in applications requiring enhanced durability and structural integrity. To address these challenges, the incorporation of natural fibres such as coconut fibres into SCC has emerged as a promising solution. Coconut Fibre Reinforced Self-Compacting Concrete (CFRSCC) is an innovative material that combines the advantages of SCC with the mechanical benefits of coconut fibres. Coconut fibres are abundant, renewable, and environmentally friendly, making them a sustainable choice for reinforcement. The addition of these fibres improves the tensile strength, ductility, and crack resistance of SCC, thus enhancing its overall performance. This study compares the properties of CFRSCC with traditional SCC, focusing on key parameters such as compressive strength, tensile strength, flexural strength, and durability. The results indicate that CFRSCC exhibits superior mechanical properties, including increased tensile and flexural strength due to the bridging effect of the fibres, which helps to arrest crack propagation and improve post-cracking behavior. Furthermore, the enhanced ductility of CFRSCC contributes to greater energy absorption and deformation capacity, making it more resilient under dynamic and impact loads. In terms of sustainability, CFRSCC leverages agricultural waste products, thereby reducing the reliance on synthetic fibres and contributing to waste management and environmental conservation. The utilization of coconut fibres also offers economic benefits, particularly in regions where coconut production is prevalent, by providing a value-added use for by-products that would otherwise be discarded. In conclusion, CFRSCC presents a superior alternative to traditional SCC by addressing its limitations and offering enhanced mechanical performance, sustainability, and economic advantages. This innovative material holds significant potential for a wide range of construction applications, promoting more durable, resilient, and eco-friendly infrastructure development.

Directly Converting Bulk Wood into Branch Micro-Nano Fibers to Synergistically Enhance the Strength and Toughness via Interface Engineering.

Hierarchical biobased micro/nanomaterials offer great potential as the next-generation building blocks for robust films or macroscopic fibers with high strength, while their capability in suppressing crack propagation when subject to damage is hindered by their limited length. Herein, we employed an approach to directly convert bulk wood into fibers with a high aspect ratio and nanosized branching structures. Particularly, the length of microfibers surpassed 1 mm with that of the nanosized branches reaching up to 300 μm. The presence of both interwoven micro- and nanofibers endowed the product with substantially improved tensile strength (393.99 MPa) and toughness (19.07 MJ m-3). The unique mechanical properties arose from mutual filling and the hierarchical deformation facilitated by branched nanofibers, which collectively contributed to effective energy dissipation. Hence, the nanotransformation strategy opens the door toward a facial, scalable method for building high-strength film or macroscopic fibers available in various advanced applications.

Exploring fracture anisotropy in tantalum carbide compounds: A density functional theory approach

AbstractIn this paper, we examine the cleavage fracture anisotropy in tantalum carbides, namely, TaC, α‐Ta2C, and ζ‐Ta4C3 − x, using density functional theory (DFT) calculations. Our investigation identifies the presence of multiple low‐energy cleavage planes indicating multiple potential pathways for crack propagation in these ceramics, even the low symmetry compounds. The anisotropy characteristics of cleavage fractures exhibited by α‐Ta2C and ζ‐Ta4C3 − x closely align with the intrinsic fracture anisotropy observed in TaC. Notably, there exist at least three pyramidal planes in ζ‐Ta4C3 − x whose cleavage energies are less than those of the carbon‐depleted basal planes, previously reported to have the lowest cleavage energy. The observed preference in experiments for cleavage along carbon‐depleted basal planes, exclusive of other identified low‐energy planes, points to factors beyond cleavage energy influencing cleavage plane preference.

Surface crack propagation of electroplated chromium coating and cotton fabric with dry friction

Electroplated chromium coatings are commonly used to improve the wear resistance of metal parts in the cotton textile industry, and surface crack is an important feature. This study investigates the tribological properties and surface crack propagation of the electroplated chromium coating in dry friction contact with cotton fabric. It is found that the coating has excellent tribological properties, with the friction coefficient eventually stabilized at 0.11 and the average wear rate of 0.0038 mm3/h. The cotton fabric mainly exhibits a polishing effect on the coating during friction, and the failure of the coating is in the form of delamination failure within the coating. Crack propagation is mainly due to the friction of cotton fabric, the main cracks of the mesh crack structure hardly propagate, while the short cracks extending on the main cracks undergo propagation behavior. Short cracks propagate vertically along the friction direction and eventually develop into the main crack level. The tangential stress generated by friction acts on the crack tip, which is the main cause of crack propagation. The plastic zone generated at the crack tip affects the distribution of the stress field and the effect of the plastic zone on crack propagation is analyzed.

Failure of adhesive bonding unveiled by in-situ strain testing by high-resolution scanning transmission electron microscopy

The nano-scale failure behaviors of adhesive interfaces were investigated through in-situ straining testing to observe real-time crack propagations under a scanning transmission electron microscope (STEM). Two different loading modes were applied to thin sections of adhesive interfaces: crack-opening mode applied to pre-cracks made at the interface and shear mode. The failure of aluminum alloy (Al6061) and a second-generation acrylic adhesive (SGA) was examined, enabling observation of the growth of crazing in the adhesive layer, which has a phase-separated structure, preceding the macroscopic failure of the interfaces. Furthermore, the failure of a direct joint of thermoplastic and Al was investigated, with a comparison made to that observed in the adhesive interface. The generation and propagation of cracks near the interface, attributed to the adhesive's phase separation, contribute to the toughness of the adhesive interface. Both the direction of stress acting on the interface and the interface's strength influence the initiation and growth of cracks throughout the adhesive layer.

Multi-scale study on the mechanical properties of concrete based on crack propagation under hygrothermal coupling

During the long-term service of structures, the environmental temperature and humidity fields can lead to the evolution of the pore structure within concrete materials, thereby affecting changes in mechanical properties. However, the mechanisms of their influence still need further clarification and are challenging to correlate for prediction. Addressing this specific issue, the current study focuses on evaluating 78 cubic concrete specimens with C30 and C40 strength grades. These specimens were subjected to a 95 % humidity environment at temperatures of 40 °C, 60 °C, and 80 °C for durations of 30, 60, and 90 days. The research involved conducting both microstructural and macroscopic mechanical tests to quantify the evolution of internal hydrates, pore structures, and pore distribution, as well as to assess the changes in the macroscopic mechanical properties of the specimens. To accurately predict the process, a multiscale finite element model (FEM) based on the bilinear continuum cohesive damage model was established. This model quantifies the changes in mechanical properties of mesoscopic three-phase concrete due to microcrack evolution under hygrothermal coupling. To facilitate multiscale simulations between the Representative Volume Element (RVE) and macroscopic scale models, relevant subroutines were written using Umath, and parallel computing was employed to reduce the computational burden. For the macroscopic model in this study, a homogenized concrete cube model with dimensions identical to the experimental specimens was selected. The effectiveness of the parallel computational model was validated by comparing and analyzing the simulation results under uniaxial compression with the experimental data. The findings indicate that hygrothermal action leads to the initiation and expansion of microcracks within the concrete, thereby impacting the alteration of its mechanical properties. In addition, the parallel computing-based multiscale FEM can more accurately quantify the typical damage process of crack propagation while reducing the computational load and may provide relatively accurate predictions of the mechanical characteristics of concrete under the influence of hygrothermal coupling, ensuring effective modeling of macroscopic structural specimens in various temperature and humidity environments.

Real-time and visual monitoring coating damage and metal corrosion based on the multiple chromatic transition of TMB triggered by highly active N-CDs/Fe3O4 peroxidase mimics and Fe3+

Self-reporting corrosion protection coatings offer effective means to detect potential failures in advance, allowing for timely maintenance and extending the lifespan of metal materials. However, there currently remains a challenge in developing techniques capable of concurrently monitoring coating damage and metal corrosion throughout a procedure. Herein, N-CDs/Fe3O4 hybrid nanoparticles with high peroxidase-like activity were fabricated through a two-step hydrothermal process which exhibit superior affinity (Km=1.2 mM) towards H2O2 than HRP and effectively turn-on the color of TMB. Combined with the excellent responsiveness towards 8-HQ and the strict linear dependent relationships towards Fe3+ (ranging from 0.75 to 15.15 μM), a novel colorimetric assay is established to not only turn on the signals to report the appearance of damage, but additionally switch the colors of TMB system to reveal the possible crack propagation and metal corrosion underneath. Moreover, the pre-existing corrosion, characterized by higher Fe3+ concentration, is successfully indicated according to the color intensity enhancement compared with pristine metal sheet. Notably, such a multifunctional colorimetric assay enables the real-time and visual monitoring coating damage and metal corrosion simply through a Python program integrated into smartphones, serving as a promising strategy for promptly alerting of potential structural failures.