Pub Date : 2025-12-26DOI: 10.1016/j.engfracmech.2025.111823
Xiao-Ping Zhou, Er-Bao Du
In this paper, a three-dimensional adaptive non-uniform discretization for the non-local method (TANDNM) is established to simulate crack propagation behaviors, in which the stochastic idea of Monte-Carlo method is developed to calculate the volume of material points, and the Vectorization and Logical Operators (VLO) are proposed to obviously improve the computational efficiency. The proposed method can successfully realize the adaptive non-uniform discretization of material points without knowing the crack path in advance. Moreover, a positioning method based on polygon edge-by-edge traversal for new material point interpolation in Delaunay triangular mesh is proposed, which overcomes the shortcomings of the Ray-Casting Algorithm. Several numerical cases are illustrated to verify the computational results of the proposed method. The results obtained by the proposed method are in good agreement with those obtained by the traditional peridynamics and other methods.
{"title":"A three-dimensional adaptive non-uniform discretization for the non-local method in solid fracture","authors":"Xiao-Ping Zhou, Er-Bao Du","doi":"10.1016/j.engfracmech.2025.111823","DOIUrl":"10.1016/j.engfracmech.2025.111823","url":null,"abstract":"<div><div>In this paper, a three-dimensional adaptive non-uniform discretization for the non-local method (TANDNM) is established to simulate crack propagation behaviors, in which the stochastic idea of Monte-Carlo method is developed to calculate the volume of material points, and the Vectorization and Logical Operators (VLO) are proposed to obviously improve the computational efficiency. The proposed method can successfully realize the adaptive non-uniform discretization of material points without knowing the crack path in advance. Moreover, a positioning method based on polygon edge-by-edge traversal for new material point interpolation in Delaunay triangular mesh is proposed, which overcomes the shortcomings of the Ray-Casting Algorithm. Several numerical cases are illustrated to verify the computational results of the proposed method. The results obtained by the proposed method are in good agreement with those obtained by the traditional peridynamics and other methods.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111823"},"PeriodicalIF":5.3,"publicationDate":"2025-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145882177","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-20DOI: 10.1016/j.engfracmech.2025.111801
Lu Xiao , Jingli Ren
We propose an information mining-assisted machine learning framework to predict the fatigue life of aluminum alloys. This framework aims to improve model’s performance by integrating mined information into modeling process. Specifically, it employs genetic programming-based symbolic regression (SR) to mine underlying information, which describes a relationship between key material parameters (stress amplitude, maximum stress, ultimate tensile strength) and fatigue life. The mined relationship is then integrated into modeling for fatigue life prediction. Experimental datasets of various aluminum alloys, multi-principal element alloys, and steels are utilized to evaluate the proposed framework. The results demonstrate that the SR-assisted models achieve superior accuracy and generalization (R 0.8) to the black-box models (R 0.8). Moreover, interpretability analysis revealed that high concentrations of Mg, Zn, Zr, Cr, Mn, and Cu are beneficial to the fatigue strength of aluminum alloys. The proposed framework provides a more general and accurate approach for fatigue life prediction than conventional methods, thereby offering more reliable support for the risk assessment of structural components.
{"title":"Information mining-assisted fatigue life prediction of aluminum alloys","authors":"Lu Xiao , Jingli Ren","doi":"10.1016/j.engfracmech.2025.111801","DOIUrl":"10.1016/j.engfracmech.2025.111801","url":null,"abstract":"<div><div>We propose an information mining-assisted machine learning framework to predict the fatigue life of aluminum alloys. This framework aims to improve model’s performance by integrating mined information into modeling process. Specifically, it employs genetic programming-based symbolic regression (SR) to mine underlying information, which describes a relationship between key material parameters (stress amplitude, maximum stress, ultimate tensile strength) and fatigue life. The mined relationship is then integrated into modeling for fatigue life prediction. Experimental datasets of various aluminum alloys, multi-principal element alloys, and steels are utilized to evaluate the proposed framework. The results demonstrate that the SR-assisted models achieve superior accuracy and generalization (R<span><math><msup><mrow></mrow><mrow><mn>2</mn></mrow></msup></math></span> <span><math><mo>></mo></math></span> 0.8) to the black-box models (R<span><math><msup><mrow></mrow><mrow><mn>2</mn></mrow></msup></math></span> <span><math><mo><</mo></math></span> 0.8). Moreover, interpretability analysis revealed that high concentrations of Mg, Zn, Zr, Cr, Mn, and Cu are beneficial to the fatigue strength of aluminum alloys. The proposed framework provides a more general and accurate approach for fatigue life prediction than conventional methods, thereby offering more reliable support for the risk assessment of structural components.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111801"},"PeriodicalIF":5.3,"publicationDate":"2025-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145838695","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-20DOI: 10.1016/j.engfracmech.2025.111817
Tianbao Qian , Yao Cheng , Shuang Sun , Longyan Zhao , Qingyu Liu , Zuquan Hu , Chuan Ye , Zhu Zeng
Natural mineralized biomaterials are renowned for exceptional mechanical properties, primarily attributed to their hierarchical structures. However, the mechanisms underlying the toughening of hierarchical inorganic mineral nanostructures during macroscopic deformation remain insufficiently understood and warrant further investigation. In this study, we utilized an in situ atomic force microscopy (AFM)-mechanical testing platform to scrutinize the deformation behaviors of inorganic mineral nanostructures in nacre and bone during the initiation of crack. Our results reveal that, when subjected to external forces, both nacre and bone predominantly undergo deformation of the mineral phase through the formation and reorganization of mineral aggregates. Specifically, in nacre, aragonite nano-granular aggregates are reorganized into clusters of beaded grains, while in bone, hydroxyapatite mineral aggregates interact synergistically with collagen fibrils, thereby modulating submicron crack orientations and increasing the likelihood of crack deflection. The interfacial submicron cracks that develop between mineral aggregates significantly influence the path of crack propagation during external loading. This in situ investigation of nanoscale hierarchical mineral structures enhances our understanding of the inorganic phase’s role in degenerative bone pathologies, and the mechanical effect of mineral aggregates in regulating crack propagation in natural mineralized materials will provide critical insights for advancing biomimetic design in particle-reinforced composites.
{"title":"Failure nano-interface evolution mechanisms in natural mineralized materials – Mineral aggregation-mediated multiscale toughening effects","authors":"Tianbao Qian , Yao Cheng , Shuang Sun , Longyan Zhao , Qingyu Liu , Zuquan Hu , Chuan Ye , Zhu Zeng","doi":"10.1016/j.engfracmech.2025.111817","DOIUrl":"10.1016/j.engfracmech.2025.111817","url":null,"abstract":"<div><div>Natural mineralized biomaterials are renowned for exceptional mechanical properties, primarily attributed to their hierarchical structures. However, the mechanisms underlying the toughening of hierarchical inorganic mineral nanostructures during macroscopic deformation remain insufficiently understood and warrant further investigation. In this study, we utilized an in situ atomic force microscopy (AFM)-mechanical testing platform to scrutinize the deformation behaviors of inorganic mineral nanostructures in nacre and bone during the initiation of crack. Our results reveal that, when subjected to external forces, both nacre and bone predominantly undergo deformation of the mineral phase through the formation and reorganization of mineral aggregates. Specifically, in nacre, aragonite nano-granular aggregates are reorganized into clusters of beaded grains, while in bone, hydroxyapatite mineral aggregates interact synergistically with collagen fibrils, thereby modulating submicron crack orientations and increasing the likelihood of crack deflection. The interfacial submicron cracks that develop between mineral aggregates significantly influence the path of crack propagation during external loading. This in situ investigation of nanoscale hierarchical mineral structures enhances our understanding of the inorganic phase’s role in degenerative bone pathologies, and the mechanical effect of mineral aggregates in regulating crack propagation in natural mineralized materials will provide critical insights for advancing biomimetic design in particle-reinforced composites.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111817"},"PeriodicalIF":5.3,"publicationDate":"2025-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145838739","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-19DOI: 10.1016/j.engfracmech.2025.111788
Robbert Rietkerk, Andreas Heine, Werner Riedel
We explore the failure characteristics of high-hardness armor (HHA) and ultra-high-hardness (UHA) armor steel. We provide experimental data on the plasticity and ductility of two representative materials. A calibrated Johnson-Cook model effectively describes plasticity across multiple types of experiments. Based on this, we calibrate four different failure models, including triaxiality and Lode angle parameter-dependent variants. Among the failure models evaluated, the Chocron-Erice-Anderson model demonstrates the best performance, followed by Xue-Wierzbicki, Hosford-Coulomb, and Johnson-Cook. In comparing two parameter identification methods, we find that the combined experimental–numerical method that accounts for varying triaxiality and Lode angle parameter produces the most accurate models of material ductility.
{"title":"Calibration of triaxiality and Lode angle parameter-dependent failure models for high- and ultra-high-hardness steel based on experimental material characterization tests","authors":"Robbert Rietkerk, Andreas Heine, Werner Riedel","doi":"10.1016/j.engfracmech.2025.111788","DOIUrl":"10.1016/j.engfracmech.2025.111788","url":null,"abstract":"<div><div>We explore the failure characteristics of high-hardness armor (HHA) and ultra-high-hardness (UHA) armor steel. We provide experimental data on the plasticity and ductility of two representative materials. A calibrated Johnson-Cook model effectively describes plasticity across multiple types of experiments. Based on this, we calibrate four different failure models, including triaxiality and Lode angle parameter-dependent variants. Among the failure models evaluated, the Chocron-Erice-Anderson model demonstrates the best performance, followed by Xue-Wierzbicki, Hosford-Coulomb, and Johnson-Cook. In comparing two parameter identification methods, we find that the combined experimental–numerical method that accounts for varying triaxiality and Lode angle parameter produces the most accurate models of material ductility.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111788"},"PeriodicalIF":5.3,"publicationDate":"2025-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145881614","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-19DOI: 10.1016/j.engfracmech.2025.111816
F. Long , Z.L. Hu , X.Y. Zhang , X.F. Li
This paper presents a novel mode-I interface crack model by considering the presence of induced interfacial shear stress. By superposition, the original mode-I interface crack problem is transformed into a mixed boundary value problem. With the help of the Fourier integral transform method and dual integral equations, an analytic solution is obtained exactly. Explicit expressions for the full-field stresses and displacements, including asymptotic crack-tip fields and their angular distribution functions, of the bimaterial system with an interface crack are derived for a cracked bimaterial. The obtained results indicate that the oscillatory singularity does not occur and the inverse-square root singularity is exhibited. The fracture parameters such as the stress intensity factors (SIF) and the energy release rate (ERR) are derived in closed form and compared with the classical counterparts, thereby resolving the contradictions inherent in the classical mode-I interface crack model. We find that the mode-I SIF for an interfacially cracked bimaterial is independent of the material properties, but the ERR and the crack opening displacement at the crack center depend on the material properties of both dissimilar media. The influence of the material properties on the crack initiation angle is analyzed. An interface mode-I crack advances along the interface for a usual bimaterial, whereas the crack propagation path deviates from the original interface when Dundurs’ second parameter exceeds 0.5, which occurs when one material is auxetic (with a negative Poisson’s ratio) and another is conventional material.
{"title":"An interface crack model of a bimaterial plane with consideration of the induced interfacial shear stress","authors":"F. Long , Z.L. Hu , X.Y. Zhang , X.F. Li","doi":"10.1016/j.engfracmech.2025.111816","DOIUrl":"10.1016/j.engfracmech.2025.111816","url":null,"abstract":"<div><div>This paper presents a novel mode-I interface crack model by considering the presence of induced interfacial shear stress. By superposition, the original mode-I interface crack problem is transformed into a mixed boundary value problem. With the help of the Fourier integral transform method and dual integral equations, an analytic solution is obtained exactly. Explicit expressions for the full-field stresses and displacements, including asymptotic crack-tip fields and their angular distribution functions, of the bimaterial system with an interface crack are derived for a cracked bimaterial. The obtained results indicate that the oscillatory singularity does not occur and the inverse-square root singularity is exhibited. The fracture parameters such as the stress intensity factors (SIF) and the energy release rate (ERR) are derived in closed form and compared with the classical counterparts, thereby resolving the contradictions inherent in the classical mode-I interface crack model. We find that the mode-I SIF for an interfacially cracked bimaterial is independent of the material properties, but the ERR and the crack opening displacement at the crack center depend on the material properties of both dissimilar media. The influence of the material properties on the crack initiation angle is analyzed. An interface mode-I crack advances along the interface for a usual bimaterial, whereas the crack propagation path deviates from the original interface when Dundurs’ second parameter <span><math><mfenced><mrow><mi>β</mi></mrow></mfenced></math></span> exceeds 0.5, which occurs when one material is auxetic (with a negative Poisson’s ratio) and another is conventional material.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111816"},"PeriodicalIF":5.3,"publicationDate":"2025-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145838694","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-18DOI: 10.1016/j.engfracmech.2025.111815
Andrzej Katunin , Marcin Bilewicz , Dominik Wachla , Jafar Amraei , Tomasz Rogala , Roman Minikayev , Magdalena Osial
This study investigates the fatigue behavior and damage mechanisms of self-reinforced polypropylene/polycarbonate (PP/PC) composites manufactured using the shear-controlled orientation injection molding (SCORIM) technique. Microstructural characterization confirmed a layered morphology with PP as the matrix and PC dispersed as spherical inclusions, leading to anisotropic mechanical properties. Thermo-mechanical fatigue tests combined with the increasing amplitude tests established a fatigue strength of 19.4 MPa. Infrared thermography identified a critical self-heating temperature of ∼50 °C as the onset of macroscopic crack front formation, while final failure was associated with localized temperatures exceeding 110 °C due to frictional heating. Scanning electron microscope (SEM) revealed ductile fibrillation and crazing in the core, brittle fracture in outer layers, and interlayer delamination with pull-out mechanism. X-ray diffraction (XRD) showed preserved α-PP monoclinic structure with slight orientation loss after fatigue, while thermogravimetric analysis (TGA) and Fourier transform infrared spectroscopy (FTIR) analysis confirmed thermal stability without chemical degradation. The results highlight the interplay of microstructure, anisotropy, and thermomechanical effects governing fatigue performance of SCORIM-processed PP/PC composites.
{"title":"Fatigue and fracture of self-reinforced polypropylene/polycarbonate composites at the presence of self-heating effect","authors":"Andrzej Katunin , Marcin Bilewicz , Dominik Wachla , Jafar Amraei , Tomasz Rogala , Roman Minikayev , Magdalena Osial","doi":"10.1016/j.engfracmech.2025.111815","DOIUrl":"10.1016/j.engfracmech.2025.111815","url":null,"abstract":"<div><div>This study investigates the fatigue behavior and damage mechanisms of self-reinforced polypropylene/polycarbonate (PP/PC) composites manufactured using the shear-controlled orientation injection molding (SCORIM) technique. Microstructural characterization confirmed a layered morphology with PP as the matrix and PC dispersed as spherical inclusions, leading to anisotropic mechanical properties. Thermo-mechanical fatigue tests combined with the increasing amplitude tests established a fatigue strength of 19.4 MPa. Infrared thermography identified a critical self-heating temperature of ∼50 °C as the onset of macroscopic crack front formation, while final failure was associated with localized temperatures exceeding 110 °C due to frictional heating. Scanning electron microscope (SEM) revealed ductile fibrillation and crazing in the core, brittle fracture in outer layers, and interlayer delamination with pull-out mechanism. X-ray diffraction (XRD) showed preserved α-PP monoclinic structure with slight orientation loss after fatigue, while thermogravimetric analysis (TGA) and Fourier transform infrared spectroscopy (FTIR) analysis confirmed thermal stability without chemical degradation. The results highlight the interplay of microstructure, anisotropy, and thermomechanical effects governing fatigue performance of SCORIM-processed PP/PC composites.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111815"},"PeriodicalIF":5.3,"publicationDate":"2025-12-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145789714","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-17DOI: 10.1016/j.engfracmech.2025.111814
Xin Song, Huiping Qi, Ning Han, Yong Hu, Wen Yang, Zhenjiang Li
In this study, a new semi-coupled fracture model is proposed to predict the damage evolution during the titanium alloy thread rolling process. The combined genetic algorithm(GA)-Gaussian Process Regression(GPR) optimization framework is introduced to effectively calibrate the key parameters of the damage model. A highly consistent result is observed between the model prediction results and experimental results. Then, the damage evolution during the titanium alloy thread rolling process is investigated. The predicted results show a great consistency with the actual damage of the sample. The damage mechanism during the thread rolling process of titanium alloy was analyzed through finite element simulation and EBSD test results. The theoretical framework and experimental methods established in this study construct a solid foundation for accurate damage prediction and process optimization of titanium alloys and other difficult-to-machine materials in intelligent forming manufacturing.
{"title":"Prediction of titanium alloy thread rolling damage based on machine learning assisted semi-coupled fracture criterion","authors":"Xin Song, Huiping Qi, Ning Han, Yong Hu, Wen Yang, Zhenjiang Li","doi":"10.1016/j.engfracmech.2025.111814","DOIUrl":"10.1016/j.engfracmech.2025.111814","url":null,"abstract":"<div><div>In this study, a new semi-coupled fracture model is proposed to predict the damage evolution during the titanium alloy thread rolling process. The combined genetic algorithm(GA)-Gaussian Process Regression(GPR) optimization framework is introduced to effectively calibrate the key parameters of the damage model. A highly consistent result is observed between the model prediction results and experimental results. Then, the damage evolution during the titanium alloy thread rolling process is investigated. The predicted results show a great consistency with the actual damage of the sample. The damage mechanism during the thread rolling process of titanium alloy was analyzed through finite element simulation and EBSD test results. The theoretical framework and experimental methods established in this study construct a solid foundation for accurate damage prediction and process optimization of titanium alloys and other difficult-to-machine materials in intelligent forming manufacturing.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111814"},"PeriodicalIF":5.3,"publicationDate":"2025-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145789800","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.engfracmech.2025.111813
Xiang Chen , Xi Liu , Jinwen Huang , Zhonghua Yan , Xi Kang
Uranium, the most stable form of uranium crystals, significantly impacts nuclear industries, materials science, and medicine. However, its complex mechanisms of plastic deformation present challenges in engineering and service applications. To address these challenges, extensive research has been conducted on compression and tensile experiments involving α-uranium; however, its numerical models remain underdeveloped. This study integrates custom subroutine Umat with user-defined element Uel, using crystal plasticity models and cohesive elements to simulate the tensile properties of α-uranium and investigate the effects of defect geometry and gradient grain boundary cracks on its mechanical performance. Through cumulative plastic strain contour maps, analyze plastic strain accumulation during crack initiation and propagation. Additionally, introduce various geometric defects, characterizing their morphology and angles, and extend the model to a 3D discrete polycrystalline finite element model to examine grain orientation and size effects on material properties and fracture behavior. The results show that the proposed crystal plasticity model effectively simulates α-uranium’s tensile and fracture behaviors. In the presence of defects, cracks mainly concentrate on local shapes perpendicular to the loading direction, with significant strain concentration near sharp corners. Grain size differences cause stress concentration between grains, initiating and propagating cracks, reducing material strength and fracture toughness.
{"title":"Finite element tensile fracture analysis of α-uranium based on 3D crystal plastic model and cohesive element","authors":"Xiang Chen , Xi Liu , Jinwen Huang , Zhonghua Yan , Xi Kang","doi":"10.1016/j.engfracmech.2025.111813","DOIUrl":"10.1016/j.engfracmech.2025.111813","url":null,"abstract":"<div><div>Uranium, the most stable form of uranium crystals, significantly impacts nuclear industries, materials science, and medicine. However, its complex mechanisms of plastic deformation present challenges in engineering and service applications. To address these challenges, extensive research has been conducted on compression and tensile experiments involving α-uranium; however, its numerical models remain underdeveloped. This study integrates custom subroutine Umat with user-defined element Uel, using crystal plasticity models and cohesive elements to simulate the tensile properties of α-uranium and investigate the effects of defect geometry and gradient grain boundary cracks on its mechanical performance. Through cumulative plastic strain contour maps, analyze plastic strain accumulation during crack initiation and propagation. Additionally, introduce various geometric defects, characterizing their morphology and angles, and extend the model to a 3D discrete polycrystalline finite element model to examine grain orientation and size effects on material properties and fracture behavior. The results show that the proposed crystal plasticity model effectively simulates α-uranium’s tensile and fracture behaviors. In the presence of defects, cracks mainly concentrate on local shapes perpendicular to the loading direction, with significant strain concentration near sharp corners. Grain size differences cause stress concentration between grains, initiating and propagating cracks, reducing material strength and fracture toughness.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"333 ","pages":"Article 111813"},"PeriodicalIF":5.3,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145838740","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.engfracmech.2025.111812
Zahra Khaji , Mahdi Fakoor , Saeed Shakhesi
The reliable design of electronic boards is critical due to their exposure to severe service conditions and the high cost of failure. These boards are susceptible to interfacial cracking, particularly in solder joints or at board/solder interfaces, initiated by microcracks and driven toward catastrophic failure under mixed-mode I/II loading. Such conditions generate a fracture process zone (FPZ) where microcracking and other energy-absorbing mechanisms significantly influence crack propagation. Accurately capturing both microcrack evolution and macrocrack growth is therefore essential for predicting fracture onset. This study introduces a novel micromechanical criterion for predicting interfacial fractures between orthotropic electronic boards and isotropic solder joints under mixed-mode I/II loading. The orthotropic electronic board is modeled using the Reinforced Isotropic Solid (RIS) conceptual framework. We establish relationships for the maximum Strain Energy Release Rate (SERR) that governs interfacial cracks between these dissimilar materials. Importantly, to address significant energy dissipation within the damage zone, we develop enhanced SERR relationships tailored to this region. This improvement greatly enhances the criterion’s predictive capability for fracture initiation. The main findings demonstrate that the proposed criterion produces fracture limit curves (FLCs) that are strongly aligned with established experimental data from the literature, showing a deviation of approximately 5–10%. Specifically, the model successfully predicts a consistent dominance of microcracks within the damage zone. Additionally, an increase in the microcrack density parameter () significantly shifts the theoretical FLCs, causing them to asymptotically converge with the experimental results. This confirms that an accurate micromechanical representation of the damage zone is crucial for precise fracture prediction. The validated framework thus provides a robust predictive tool for assessing interfacial fracture in electronic assemblies, directly linking micro-scale damage mechanisms to macroscopic fracture behavior, and ultimately improving reliability in critical electronic applications.
{"title":"A micromechanical framework for predicting interfacial fracture in electronic boards using strain energy release rate concept","authors":"Zahra Khaji , Mahdi Fakoor , Saeed Shakhesi","doi":"10.1016/j.engfracmech.2025.111812","DOIUrl":"10.1016/j.engfracmech.2025.111812","url":null,"abstract":"<div><div>The reliable design of electronic boards is critical due to their exposure to severe service conditions and the high cost of failure. These boards are susceptible to interfacial cracking, particularly in solder joints or at board/solder interfaces, initiated by microcracks and driven toward catastrophic failure under mixed-mode I/II loading. Such conditions generate a fracture process zone (FPZ) where microcracking and other energy-absorbing mechanisms significantly influence crack propagation. Accurately capturing both microcrack evolution and macrocrack growth is therefore essential for predicting fracture onset. This study introduces a novel micromechanical criterion for predicting interfacial fractures between orthotropic electronic boards and isotropic solder joints under mixed-mode I/II loading. The orthotropic electronic board is modeled using the Reinforced Isotropic Solid (RIS) conceptual framework. We establish relationships for the maximum Strain Energy Release Rate (SERR) that governs interfacial cracks between these dissimilar materials. Importantly, to address significant energy dissipation within the damage zone, we develop enhanced SERR relationships tailored to this region. This improvement greatly enhances the criterion’s predictive capability for fracture initiation. The main findings demonstrate that the proposed criterion produces fracture limit curves (FLCs) that are strongly aligned with established experimental data from the literature, showing a deviation <span><math><mrow><msub><mi>K</mi><mrow><mi>II</mi></mrow></msub></mrow></math></span> of <span><math><mrow><msub><mi>K</mi><mi>I</mi></msub></mrow></math></span> approximately 5–10%. Specifically, the model successfully predicts a consistent dominance of microcracks within the damage zone. Additionally, an increase in the microcrack density parameter (<span><math><mrow><mi>ε</mi></mrow></math></span>) significantly shifts the theoretical FLCs, causing them to asymptotically converge with the experimental results. This confirms that an accurate micromechanical representation of the damage zone is crucial for precise fracture prediction. The validated framework thus provides a robust predictive tool for assessing interfacial fracture in electronic assemblies, directly linking micro-scale damage mechanisms to macroscopic fracture behavior, and ultimately improving reliability in critical electronic applications.</div></div>","PeriodicalId":11576,"journal":{"name":"Engineering Fracture Mechanics","volume":"332 ","pages":"Article 111812"},"PeriodicalIF":5.3,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787462","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-15DOI: 10.1016/j.engfracmech.2025.111811
Xiaobo Cao , Wei Li , Yuzhe Jin , Zifan Hu , Chuanwen Sun , Ahmad Serjouei , Liang Cai , Pilin Song
Fatigue crack growth (FCG) is a critical mode of performance degradation and failure in perfluorinated sulfonic-acid ionomers. However, the underlying damage mechanisms associated with microstructure and failure characteristics are not yet well understood. To address this gap, the FCG behavior of a PFSA membrane was investigated through a combined theoretical, numerical, and multiscale experimental approach, encompassing microscopic fracture morphology, mesoscopic crack tip stress distribution, and macroscopic FCG rate. The results show that FCG exhibits a progressive failure mechanism, primarily characterized by features such as microvoid nucleation and coalescence in high-stress regions, as along with step-like morphology on the fracture surface. Analysis of the mesoscopic crack tip strain field revealed distinct strain gradient effects and butterfly-shaped plastic zone, both of which intensify with increasing stress ratio. An anisotropic viscoelastic-plastic constitutive model, incorporating stress status, was integrated with a cyclic cohesive zone model to establish a progressive fatigue damage framework. This model effectively captured strain distribution near the crack tip and reproduced the observed FCG rates. Finally, a multiscale validation method established the correlation between macroscopic mechanical response and microscopic damage evolution. These findings reveal the multiscale characteristic of fatigue failure in PFSA ionomers and contribute to a more comprehensive framework for understanding their fracture mechanisms.
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