Suppress Crack Propagation Research Articles

Dynamic Lithium Transport Pathway via Crack Formation in Phase-Separating Materials

Degradation of electrode particles during cycling is chemo-mechanically coupled and needs to be systematically investigated for the Li-ion battery development. The effect of Li transport pathway on internal stress and crack formation during cycling remains elusive. The opposite effect of cracked, newly exposed active surface on Li transport pathway alteration, accelerating the chemo-mechanical degradation, also remains poorly known. Using operando scanning transmission X-ray microscopy on [100]-oriented LiFePO4 single particles, we demonstrated that lithium insertion from the edge of the non-cracked particle dynamically generate tensile stress within the particle, thereby initiating crack formation during lithiation. The exposed crack surface acts as a Li (de)insertion hotspot, redirecting Li transport pathway and internal stress-fields. Delithiation process induces the Li-poor phase around the crack, creating tensile stress, propagating the crack, and subsequently exposing fresh surface which serves as active hot-spot. On the other hands, lithiation process induces the Li-rich phases around the crack, creating compressive stress and suppressing crack propagation. Phase-field simulations demonstrate chemo-mechanically interactive loop that lithium (de)insertion pathway determines dynamic tensile/compressive stress distribution, which recursively determines (de)insertion pathway. This study offers insights that can help develop high-performance and long-lasting batteries, as well as cycling protocols that suppress crack formation. Figure 1

Enhancing shear strength in hybrid metal-composite single-lap joints using Z-pins fabricated via fused filament fabrication

This paper investigates the interfacial shear strength of hybrid metal-composite single-lap joints (SLJs) reinforced with stainless steel Z-pins fabricated by fused filament fabrication (FFF). The joints were created by 3D printing an orthogonal array of 2 mm diameter steel Z-pins onto a steel substrate using FFF. The Z-pins were then embedded into a basalt fibre (BF)-fabric/epoxy resin composite using the Ultrasonically Assisted Z-Fibre™ (UAZ) method to form a high-strength and tough interface. The results demonstrate that steel Z-pins produced via FFF effectively enhance the shear strength of the hybrid metal-composite SLJs, significantly improving joint performance. The study also explores the influence of Z-pin volume fraction and embedding height on SLJ shear strength. It was found that higher volume fractions and greater embedding heights of the Z-pins contribute to the increased shear strength. Compared to unreinforced joints, the maximum shear strength of the steel Z-pin reinforced joints increased by 120.1 %. This enhancement is attributed to the effective energy absorption mechanisms, primarily facilitated by the frictional pull-out, plastic deformation and shear fracture of Z-pins accompanied by the formation of ductile dimples. These mechanisms suppress crack propagation and improve joint integrity. This study presents an innovative approach for fabricating hybrid metal-composite joints with enhanced toughness and strength.

A novel approach to enhance the structural integrity of a bottom-edge cracked I-beam with piezoelectric actuators

Structural health monitoring and repair have become increasingly crucial in confirming the safety and longevity of damaged structures. This study presents a novel approach to enhancing the structural integrity and extending the fatigue life of a bottom-edge cracked I-beam by applying piezoelectric actuators strategically placed along the crack location by actively suppressing crack propagation. An innovative actuation system induces controlled deformations in the I-beam, effectively reducing the Stress Intensity Factor (SIF) and preventing crack propagation. The efficacy of the proposed approach is validated through a series of numerical results on the ABAQUS platform, including static loading, fatigue loading, and crack growth monitoring. Various parameters, like maximum loading capacity under static loading, interpretation of crack growth rate, and service life, are monitored and analyzed throughout the cyclic loading process. The results demonstrate that the application of 500 V to the piezoelectric actuators significantly reduces the SIF by 16.62% under a 2 kN total load, a 2.86% enhanced maximum load-carrying capacity is obtained, delayed crack propagation is found after repair, and a 72.67% extended service life is achieved under a load range of 0.2 kN to 2 kN. Overall, the outcomes of this research lead to the development of innovative and efficient techniques for delaying the propagation of cracks, thereby preventing the premature onset of catastrophic failure of cracked I-beams.

Experimental study on interaction characteristics of explosive cracks under confining pressure and its comparison with free boundary results

The influence of confining pressure on the dynamic fracture mechanical behavior of deep rock masses is crucial in the exploitation of deep resources and the development of underground spaces. In this study, dynamic caustics experiments were conducted using transparent epoxy resin materials to investigate the crack propagation behavior and interaction mechanisms of double cracks under confinement. The experimental results indicate that biaxial confining pressure suppresses crack propagation, interaction between double cracks, and penetration. Without confining pressure, cracks do not penetrate until the relative vertical distance ΔH between crack tips is 20 mm, whereas with confining pressure, cracks cease to penetrate when the relative vertical distance between crack tips is 10 mm; however, interaction between crack tips still exists at this point. During the crack interaction stage, both fracture toughness and propagation velocity of crack tips exhibit significant fluctuations under no confining pressure conditions, whereas under confining pressure, both decrease rapidly. Additionally, under confining pressure conditions, the fluctuation range of crack propagation direction during crack interaction is relatively small. Confining pressure rapidly reduces the degree of stress concentration at crack tips, increases the rate of energy release at crack tips, and enhances the ability of dynamic cracks to resist the influence of other crack tips or crack surfaces. Under confining pressure, continuous Rayleigh waves are typically observed at crack tips due to an imbalance between stored strain energy and the energy release rate. These waves dissipate part of the strain energy, promoting crack deflection and branching.

Failure Prediction of an Airfoil-Type Crack in Thermoelectric Coupling Materials

Airfoil-type cracks with curved surfaces and sharp tips are frequently encountered in modern engineering applications and the aerospace industry. However, such cracks significantly threaten structures due to stress concentration and further cause damage. This study investigates the theoretical analysis and failure prediction of airfoil-type cracks within thermoelectric coupling materials under the interaction of remote mechanical loads, heat flux and electric current density. By employing complex variable theory, conformal mapping methods, and the analytic continuation theorem, the full-field stress and stress intensity factors of an airfoil-type crack were determined under three different loading conditions. The results indicate that when the airfoil-shaped crack tip is subjected to horizontal compression, vertical tensile mechanical load, and both heat flux and current density parallel to the crack, the crack tip would reach a dangerous state. Additionally, the full-field stress distribution reveals stress concentration around the crack tip, which explains variations in SIFs under different external forces and shape factors. Four critical situations suppressing crack propagation under mixed loading conditions are proposed. Furthermore, using an acrylic plate and bismuth telluride alloy as examples, the critical values of external loading for the mixed-mode fracture are determined based on the strain energy density criterion. These critical values can be used to predict failure initiation, thus reducing the risk of structural failure due to airfoil cracks within thermoelectric coupling materials.

Realizing strength-ductility combination of Ni-12Mo-7Cr-2Nb based superalloy via nano-sized MC carbides at stacking faults and grain boundaries

Developing corrosion-resistant alloys with the outstanding strength-ductility combination at elevated temperatures are highly desirable for molten salt reactor (MSR) applications. In this study, by appropriate preaging process, the yield strength and elongation of one newly developed Ni-12Mo-7Cr-2Nb based superalloy at high temperatures respectively increase by ∼50 % and ∼100 % as compared with the solid-solution state. This preaged alloy exhibits the excellent strength and overcomes the intermediate temperature embrittlement problem as compared with other alloys. Microstructure observations indicate that the strengthening and ductility improvement are related to the formation of nano-sized MC carbides. After preaging process, the extrinsic stacking faults are formed along {111} close-packed planes and decorated with ultra-dense MC carbide particles, thus are called as stacking faults precipitates (SFPs). SFPs contribute to the precipitation strengthening by the complex interaction with dislocations. Surprisingly, the SFPs exhibits the better strengthening effect than the uniformly dispersed MC carbides with the same volume fraction and size. Furthermore, it was found that the “pseudo-continuous” intergranular MC carbide particles are beneficial to the high-temperature ductility, although the similar intergranular precipitates were widely regarded as harmful in other studies. Using crystal plasticity finite element method, it was proved that the strain concentration at the triple junctions would be obviously alleviated because the intergranular MC carbide particles can suppress grain boundary sliding. If tested at 750 °C, the intergranular MC carbide particles would trigger the particle-stimulated nucleation and lead to the local dynamic recrystallization at grain boundaries and crack tips. These small recrystallized grains can suppress crack propagation and bring about the improvement in ductility in the aged alloy.

Improving interfacial microstructure and mechanical properties of ODS-W/Cu joints via anodization treatment and spark plasma sintering

The bonding properties at the interface between the first wall oxide dispersion strengthened tungsten (ODS-W) and the heat sink copper (Cu) are vital for their application in future nuclear fusion reactors. However, the immiscibility and significant differences in the coefficient of thermal expansion between ODS-W and Cu pose considerable challenges for bonding these two materials. This study utilizes anodization and hydrogen reduction processes to form a nanoporous structure on the surface of ODS-W, thereby achieving effective bonding between ODS-W and Cu by spark plasma sintering (SPS). The effects of the anodization parameters on the surface characteristics of ODS-W, and the influence of the bonding temperature on the interfacial microstructure and mechanical properties of the ODS-W/Cu joints were investigated. The results demonstrate that under an anodization condition of 50 V for 40 min, a nanoporous structure with an average pore size of about 90 nm can forms on the surfaces of ODS-W. This significantly increases the surface roughness, thereby enhancing the interfacial bonding of ODS-W with Cu during SPS. As the bonding temperature increases, the interfacial microstructure changes from linear to serrated shape, effectively suppressing crack propagation and forming a stronger mechanical interlock between ODS-W and Cu. This significantly enhances the mechanical properties of the joints. Typically, at a bonding temperature of 1000 °C, the tensile strength of the anodized ODS-W/Cu joints reaches 245.2 MPa, which is 157.9 % higher than that of directly bonded joints. Additionally, the tensile fracture primarily occurs within the Cu substrate, transitioning from brittle to ductile fracture modes.

Low cycle fatigue properties of CoCrFeNiMn high-entropy alloy with heterogeneous microstructure

Heterogeneous microstructure is a hot topic in materials science which facilitates tackling the dilemma of strength-ductility trade-off in engineering materials including high-entropy alloys. The present investigation was conducted on the impact of different microstructures including heterogeneous microstructure, constructed by thermomechanical treatment including cold rolling followed by annealing, on the monotonic and cyclic behavior of a CoCrFeNiMn high-entropy alloy. The tailored microstructure contained three features: non-recrystallized as a hard domain, ultrafine-recrystallized, and fine-recrystallized regions. A desirable combination of strength and ductility including UTS of ∼1.1 GPa together with an elongation of ∼15 % was achieved due to benefiting from hetero-deformation-induced hardening and activation of deformation twins in the fine recrystallized grains. Regarding low-cycle fatigue behavior, at the strain amplitude of 0.4 %, heterogeneous microstructure exhibits remarkable fatigue properties, including high maximum stress and extraordinary lifetime (more than 2 × 105). The compelling reasons for these desirable properties are triggering deformation twins in fine recrystallized grain, the absence of brittle sigma phase as a good location of crack initiation, and the non-recrystallized area as a hard domain for suppressing crack propagation. The results suggested that the heterogeneous microstructure has significant benefits during applying low strain amplitude, however, at high strain amplitude, grain refinement is not recommended, and coarse-grained microstructure provides better properties. The present investigation is a step forward to understand the significance of heterogeneous microstructures to improve fatigue properties of high- or medium-entropy alloys.

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.

Experimental investigation on the size-dependent CFRP shear contribution in CFRP-strengthened RC shear wall

Most of the current methods for estimating the shear contribution of CFRP are based on laboratory testing of small-sized specimens. The applicability of the current codes on large-sized FRP-strengthened shear walls remains debatable. The present study addresses the problem by investigating the combined effects of structural sizes and CFRP ratios on the shear contribution of CFRP. Through experiments, a series of geometrically similar CFRP-strengthened RC shear walls were designed and subjected to a cyclic horizontal loading. From the experiments, the following results can be obtained. The application of the externally bonded CFRP strips alters the failure mode and enhances remarkably the seismic resistance by suppressing crack propagation and increasing the energy dissipation. The increasing specimen size reduces the enhancement effects of CFRP on the nominal shear strength, ductility, and energy dissipation. These findings indicate that without considering the size effect, the effective strain that reflects the shear contribution of CFRP strips are greatly overestimated by the current codes. Therefore, the present study proposed and validated an effective strain factor capturing the combined effects of the structural size and the CFRP ratio on the shear contribution of CFRP strips, serving in assessing the shear strengthening effect of CFRP on shear walls.

PAM/CNTs-Au microcrack sensor with high sensitivity and wide detection range for multi-scale human motion detection

As the quintessential material for flexible sensors, conductive hydrogels face an inherent sensitivity-sensing range paradox and electrical-mechanical balance, which significantly curtail its applicability in multiscale motion detection. Inspired by the spider slit sensor, PAM/CNTs-Au hydrogel microcrack sensor is obtained by depositing conductive gold film on the surface of PAM/CNTs hydrogel using magnetron sputtering. By modulating the cross-linking density of conductive hydrogels and the content of carbon nanotubes (CNTs), it is possible to tailor the mechanical properties and adhesion of PAM/CNTs-Au hydrogel crack-based sensors. This self-adhering flexible sensor aids in minimizing detection errors arising from mechanical mismatch between flexible sensors and human tissues. Moreover, the exceptional electrical conductivity of CNTs, coupled with their unique one-dimensional structure, facilitates the formation of an interconnected conductive network "bridge" within the hydrogel. The harmonization of electrical and mechanical attributes in the PAM/CNTs flexible substrate is achieved by finely tuning the crosslinking density of the PAM hydrogel and the content of carbon CNTs. Simultaneously, the high-conductivity "islands" formed by the Au conductive layer during stretching ensures elevated sensitivity (gauge factor (GF) = 54.89) over an extensive detection range (>1200%). The distinctive "island-bridge" configuration of the PAM/CNTs-Au hydrogel microcrack sensor effectively suppresses crack propagation, thereby markedly augmenting the sensor's stability. Successful monitoring of physiological and motion signals across various scales attests to the potential of the PAM/CNTs-Au hydrogel microcrack sensor in wearable biosensor.

Mechanical properties due to competition behavior between damage and recovery of self‐healing fiber‐reinforced ceramics

AbstractThe phenomenon caused by the competition between self‐healing and crack propagation of self‐healing fiber‐reinforced ceramics was succeeded to be quantified as a new mechanical function. To quantify, it was measured in detail that the creep deformation as time variation of the self‐healing composite under various stresses. In particular, a detailed analysis will be carried out focusing on the time variation of the creep rate. When the tensile stress of 100 MPa was applied to the self‐healing composite, the initially large creep rate decreased with time, eventually reaching zero. This behavior is considered to be achieved by self‐healing that suppresses crack propagation. The time when the creep rate reaches 0 is an important indicator of self‐healing ability and was defined as the crack arrest time. From the results of similar experiments in which the applied stress was varied, it was found that the crack arrest time increased with the applied stress. However, at 160 MPa, creep fracture occurred. From these results, it was confirmed that the maximum stress at which the competition behavior could be expressed was 153 MPa or less. Based on the obtained results, we propose a new mechanical function that utilizes the self‐healing function.

Analysis of electrode crack propagation in solid oxide fuel cell with pre-crack

The mechanical performance of solid oxide fuel cell is one of the main factors limiting its commercialization process. In order to reduce the degree of crack propagation in the cooling process and improve the stability and durability of the cell, the finite element analysis is conducted on a three-dimensional model of solid oxide fuel cell containing pre-crack. Utilizing the extended finite element method (XFEM) and fracture theory, and considering the stress distribution, length and maximum width after crack propagation and deflection angle of crack as criteria, this paper investigates the influence of various parameters, including working temperature, material properties, pre-crack angle, and pre-crack location, on pre-crack propagation behavior and proposes a solution based on material optimization and structural optimization to improve the stability of the cell. A pre-crack is set at the left boundary of the anode to analyze the influence of different operating conditions on the propagation of anode cracks in the cell. The correctness of finite element simulation is verified by comparing the simulation results with theoretical results of crack stress intensity factors in the same model. From the comprehensive analysis of the thermal stress of the cell, the crack length and maximum width after pre-crack propagation, and the two deflection angles of crack propagation, it can be seen that within the selected parameters, in order to ensure the stability of the cell and inhibit the degree of crack propagation, the operating temperature of the cell should not be lower than 1023 K, and the thermal expansion coefficient of anode should be less than 12.50×10<sup>–6</sup> K<sup>–1</sup>. In addition, when the pre-crack angle is 45° or 0.45 mm away from the bottom of anode, the maximum width after crack propagation is the smallest, and the propagation path is the most predictable. In this case, the cell is affected by the smallest crack range and the highest stability. This research provides a guidance for suppressing crack propagation in solid oxide fuel cell, improving the lifetime and promoting the commercialization process of fuel cell.

Peeling-Stiffening Self-Adhesive Ionogel with Superhigh Interfacial Toughness.

Self-adhesive materials that can directly adhere to diverse solid surfaces are indispensable in modern life and technologies. However, it remains a challenge to develop self-adhesive materials with strong adhesion while maintaining its intrinsic softness for efficient tackiness. Here, a peeling-stiffening self-adhesive ionogel that reconciles the seemingly contradictory properties of softness and strong adhesion is reported. The ionogel contains two ionophilic repeating units with distinct associating affinities, which allows to adaptively wet rough surface in the soft dissipating state for adhering, and to dramatically stiffen to the glassy state upon peeling. The corresponding modulus increases by 117 times driven by strain-rate-induced phase separation, which greatly suppresses crack propagation and results in a super high interfacial toughness of 8046 J m-2 . The self-adhesive ionogel is also transparent, self-healable, recyclable, and can be easily removed by simple moisture treatment. This strategy provides a new way to design high-performance self-adhesive materials for intelligent soft devices.

Contribution of energy dissipation to dynamic fracture resistance of the turtle carapace

The turtle carapace is a biological armor possessing superior damage tolerance. In spite of efforts to characterize the mechanical properties of such biological armor, the protection mechanisms associated with the multilayered structure of turtle carapace are largely unknown. In this study, we carry out the calculations of energy dissipation in dynamic fracture of the turtle carapace. The plastic deformation of keratin-collagen bi-layer, keratin-collagen interfacial debonding, collagen-bone interfacial debonding and crack growth in the boney layer are accounted for in the analyses. It is found that the interfacial debonding and plastic deformation of the keratin-collagen bi-layer contribute equally to toughening of the carapace at low impact velocity, while plastic energy dissipation dominates in the case of high impact velocity. As the impact velocity is increased, energy dissipation in the turtle carapace decreases at first and then increases. We reveal that the low energy dissipation of carapace at intermediate level of impact velocity is attributed to small plastic zones in the keratin-collagen bi-layer. Furthermore, we have identified the role of the waviness of the keratin-collagen and collagen-bone interfaces. The presence of wavy interfaces enhances plastic energy dissipation of the keratin-collagen bi-layer and promotes interfacial debonding, thereby suppressing crack propagation in the boney layer. The findings provide mechanistic explanations for incorporation of wavy interfaces in the multilayered structure of turtle carapace.

First-principles investigation of phase stability and effects on ductility for MoSi2 alloyed by Al and Nb

In this paper, site preference, phase stability and elastic parameters of MoSi2 for Al and Nb addition are studied using first-principles calculation. The results show that alloying elements can cause MoSi2 to change from C11b to C40 phase and the phase transition is due to the activated 1/2[[Formula: see text]11](110) slip system for C11b. [Formula: see text] ratio reveals that the ductility is enhanced after phase transition. Ductile factor [Formula: see text] based on competitive processes between micro-crack opening and dislocations emission is defined to assess the ductility of MoSi2. Interestingly, the increased ductility is due to the activated dislocation emission but suppressed crack propagation. Finally, charge density and DOS indicate that the improved ductility is due to the weakened Mo-4d and Si-3p covalent interactions.

Influence of waste tire rubber powder, polypropylene fiber and their binary blends on mitigating alkali-silica reaction

This work aims to investigate the inhibitory effect and inhibitory mechanism of waste tire rubber powder (abbreviated as WRP) and polypropylene fiber (PPF), and their binary blends on mitigating the alkali-silica reaction (ASR). To achieve this, mortar bars containing either WRP, PPF, or WRP + PPF were prepared for the accelerated mortar bar test (AMBT). The mechanism of ASR inhibition was illustrated by scanning electron microscopy (SEM), X-ray diffraction (XRD) and X-ray computed micro-tomography (X-ray CT). The results indicated that the combination of WRP and PPF showed excellent synergistic effect on improving the compressive strength of the mortar cubes. In addition, WRP could effectively alleviate ASR, but the effect depended on the particle size of WRP, with the inhibition effect of 120 mesh WRP being the best. The addition of WRP + PPF exhibited an excellent synergistic effect on the inhibition of ASR expansion, and 120 mesh WRP and PPF with a length of 9 mm and a dosage of 0.8 kg/mm3 showed the best inhibition effect when they were incorporated together. Moreover, the inhibition mechanism of WRP and PPF on ASR was physical effect: WRP consumed the swelling energy generated by water absorption of the gel through deformation, and PPF applied its own bridging effect to suppress crack propagation. Finally, the analysis of the X-ray CT scanning results showed that adding WRP and PPF to the slurry increased the porosity. With the progress of ASR, the gel filled the pores and decreased the expansion. This further revealed more about how WRP and PPF could work together to reduce the damage caused by ASR effectively.

Effect of inserting the Zr layers on the tribo-corrosion behavior of Zr/ZrN multilayer coatings on titanium alloys

In this work, tribo-corrosion behavior of Zr/ZrN multilayer coatings in simulated body fluid (SBF) was investigated. The results indicated that Zr/ZrN-7 multilayer coatings possessed superior corrosion and tribo-corrosion resistance than the single ZrN coating. The effective inhibition of corrosive medium permeating by both forming a ZrO2 passive film and a multilayer structure contributed to the superior corrosion resistance. Furthermore, the improved corrosion, as well as suppressing crack propagation by the insertion of the Zr layer, enhanced the tribo-corrosion performance. Inserting Zr layers was found to be an effective method to improve the tribo-corrosion performance of Zr/ZrN multilayer coatings.

Conflicting behavior between powdering and flaking resistance under skin pass mill process in galvannealed interstitial free steel

<abstract> <p>The failure of galvannealed (GA) coatings during press forming is an important issue for steel companies, because it results in a deteriorated product quality and reduced productivity. Powdering and flaking are thought to be the main failure modes in GA steel. However, these two modes currently lack a clear distinction, despite their different failure types. Therefore, in this study, we demonstrate that the different behaviors of these two failure modes are generated by the skin pass mill (SPM) condition and we discuss the underlying mechanism in detail using microstructural and simulation analyses. With the increase in steel elongation from 0% to 4.0% under milling force from 0 to 6 ton, a high compressive stress is produced up to −380 MPa on the surface of the steel sheet and the interface is correspondingly flattened from 0.96 to 0.53 m in Ra. This flattening weakens the mechanical interlocking effect for adhesive bonding, deteriorating the flaking resistance from 41.1 to 65.2 hat-bead contrast index (hci). In addition, the GA coating layer becomes uniformly densified via the filling of pores under compressive stress in the layer. Furthermore, the ζ phase exhibits significant plastic deformation, leading to a uniform coverage of the coating surface; this helps to suppress crack propagation. Accordingly, the powdering resistance gradually improves from 4.2 to 3.5 mm. Consequently, with the increase in SPM-realized steel sheet elongation, the powdering resistance improves whilst the flaking resistance deteriorates. Significantly for the literature, this implies that the two failure modes occur via different mechanisms and it indicates the possibility of controlling the two coating failure modes via the SPM conditions.</p> </abstract>

Method for preparing damage-resistant 3D-printed ceramics via interior-to-exterior strengthening and toughening

Despite their high strengths and moduli, the inherent brittleness of ceramics restricts their ability to resist fracture upon impact. Designing special structures can toughen ceramics and expand their application realm; however, the ceramic strength is sacrificed. To address this problem, a damage-resistant ceramic process involving both interior and exterior strengthening and toughening is proposed. In this method, a buried combustion method (BCM) was implemented while debinding alumina (Al 2 O 3 ) green bodies, and a coating method (CM) was used after sintering Al 2 O 3 parts. Experimental results show that an increase of 259% in ultimate compressive stress and an increase of 161% in energy absorption compared with untreated Al 2 O 3 parts were achieved by adopting the BCM and CM methods. In addition, a finite-element modeling method was used to study fracture mechanisms, and molecular dynamic simulations were implemented to provide insight into the strengthening and toughening mechanisms at the atomic level. • An interior-to-exterior method to strengthen and toughen ceramics was developed. • Buried combustion method and coating method could suppress crack propagation. • Finite element modeling method was carried out to study fracture mechanisms. • Molecular dynamics were used to study strengthening and toughening mechanisms.