Search Results (108)

In this study, the effects of post-weld heat treatment (PWHT) on residual stress distribution and fatigue crack propagation (FCP) behavior in linear friction welded (LFW) Ti-6Al-4V joints were investigated. Microstructural evolution in the weld center zone (WCZ), thermomechanically affected zone (TMAZ), heat-affected zone (HAZ), and base metal (BM) was characterized using scanning electron microscropy (SEM) and electron backscatter diffraction (EBSD). Mechanical properties were evaluated via Vickers hardness testing and digital image correlation (DIC)-based tensile testing. Residual stresses before and after PWHT were measured using the contour method. The LFW process introduced significant residual stresses, with tensile stresses up to 709.2 MPa in the WCZ, resulting in non-uniform fatigue crack growth behavior. PWHT at 650 °C and 750 °C effectively reduced these stresses. After PWHT, fatigue cracks propagated uniformly across the weld region, enabling reliable determination of crack growth rates. The average crack growth rates of the heat-treated specimens were comparable to those of the base metal, confirming that PWHT, particularly at 750 °C, stabilizes the fatigue crack path and relieves internal stress. Full article

This study employs molecular dynamics (MD) simulations to investigate the mechanical response and fracture behavior of penta-graphene, a novel two-dimensional carbon allotrope composed entirely of pentagonal rings with mixed sp²–sp³ hybridization and pronounced mechanical anisotropy. Atomistic simulations are carried out to evaluate the impact of structural defects on mechanical performance and to elucidate crack propagation mechanisms. The results reveal that void defects involving sp³-hybridized carbon atoms cause a more significant degradation in mechanical strength compared to those involving sp² atoms. During fracture, local atomic rearrangements and bond reconstructions lead to the formation of energetically favorable ring structures—such as hexagons and octagons—at the crack tip, promoting enhanced energy dissipation and fracture resistance. A central focus of this work is the evaluation of the critical stress intensity factor (SIF) under mixed-mode (I/II) loading conditions. The simulations demonstrate that the critical SIF is influenced by the loading phase angle, with pure mode I exhibiting a higher SIF than pure mode II. Notably, penta-graphene shows a critical SIF significantly higher than that of graphene, indicating exceptional fracture toughness that is rare among ultra-thin two-dimensional materials. This enhanced toughness is primarily attributed to penta-graphene’s capacity for substantial out-of-plane deformation prior to failure, which redistributes stress near the crack tip, delays crack initiation, and increases energy absorption. Additionally, the study examines crack growth paths as a function of loading phase angle, revealing that branching and kinking can occur even under pure mode I loading. Full article

This study presents a unique and comprehensive application of ANSYS Mechanical R19.2’s SMART crack growth feature, leveraging its capabilities to conduct an unprecedented parametric investigation into fatigue crack propagation behavior under a wide range of positive and negative stress ratios, and to provide detailed insights into the influence of hole positioning on crack trajectory. By uniquely employing an unstructured mesh method that significantly reduces computational overhead and automates mesh updates, this research overcomes traditional fracture simulation limitations. The investigation breaks new ground by comprehensively examining an unprecedented range of both positive (R = 0.1 to 0.5) and negative (R = −0.1 to −0.5) stress ratios, revealing previously unexplored relationships in fracture mechanics. Through rigorous and extensive numerical simulations on two distinct specimen configurations, i.e., a notched plate with a strategically positioned hole under fatigue loading and a cracked rectangular plate with dual holes under static loading, this work establishes groundbreaking correlations between stress parameters and fatigue behavior. The research reveals a novel inverse relationship between the equivalent stress intensity factor and stress ratio, alongside a previously uncharacterized inverse correlation between stress ratio and von Mises stress. Notably, a direct, accelerating relationship between stress ratio and fatigue life is demonstrated, where higher R-values non-linearly increase fatigue resistance by mitigating stress concentration, challenging conventional linear approximations. This investigation makes a substantial contribution to fracture mechanics by elucidating the fundamental role of hole positioning in controlling crack propagation paths. The research uniquely demonstrates that depending on precise hole location, cracks will either deviate toward the hole or maintain their original trajectory, a phenomenon attributed to the asymmetric stress distribution at the crack tip induced by the hole’s presence. These novel findings, validated against existing literature, represent a significant advancement in predictive modeling for fatigue life assessment, offering critical new insights for engineering design and maintenance strategies in high-stakes industries. Full article

In response to the high cost and environmental impact of backfill materials in Xinjiang mines, an eco-friendly, large-volume composite was developed by bonding desert-sand mortar to waste concrete. A rock-filled concrete process produced a highly flowable mortar from desert sand, cement, and fly ash. Waste concrete blocks served as coarse aggregate. Specimens were cured for 28 days, then subjected to uniaxial compression tests on a mining rock-mechanics system using water-to-binder ratios of 0.30, 0.35, and 0.40 and aggregate sizes of 30–40 mm, 40–50 mm, and 50–60 mm. Mechanical performance—failure modes, stress–strain response, and related properties—was systematically evaluated. Crack propagation was tracked via digital image correlation (DIC) and acoustic emission (AE) techniques. Failure patterns indicated that the pure-mortar specimens exhibited classic brittle fractures with through-going cracks. Aggregate-containing specimens showed mixed-mode failure, with cracks flowing around aggregates and secondary branches forming non-through-going damage networks. Optimization identified a 0.30 water-to-binder ratio (Groups 3 and 6) as optimal, yielding an average strength of 25 MPa. Among the aggregate sizes, 40–50 mm (Group 7) performed best, with 22.58 MPa. The AE data revealed a three-stage evolution—linear-elastic, nonlinear crack growth, and critical failure—with signal density positively correlating to fracture energy. DIC maps showed unidirectional energy release in pure-mortar specimens, whereas aggregate-containing specimens displayed chaotic energy patterns. This confirms that aggregates alter stress fields at crack tips and redirect energy-dissipation paths, shifting failure from single-crack propagation to a multi-scale damage network. These results provide a theoretical basis and technical support for the resource-efficient use of mining waste and advance green backfill technology, thereby contributing to the sustainable development of mining operations. Full article

Different from general underground engineering, the micro-damage prior to failure of the surrounding rock has a significant influence on the geological disposal of high-level radioactive waste. However, the quantitative research on pre-failure dilatancy damage characteristics and stress path influence of hard brittle rocks under high stress levels is insufficient currently, and especially, the stress path under simultaneous unloading of axial and confining pressures is rarely discussed. Therefore, three representative mechanical experimental studies were conducted on the Beishan granite in the pre-selected area for high-level radioactive waste (HLW) geological disposal in China, including increasing axial pressure with constant confining pressure (path I), increasing axial pressure with unloading confining pressure (path II), and simultaneous unloading of axial and confining pressures (path III). Using the deviatoric stress ratio as a reference, the evolution laws and characteristics of stress–strain relationships, deformation modulus, generalized Poisson’s ratio, dilatancy index, and dilation angle during the path bifurcation stage were quantitatively analyzed and compared. The results indicate that macro-deformation and the plastic dilatancy process exhibit strong path dependency. The critical value and growth gradient of the dilatancy parameter for path I are both the smallest, and the suppressive effect of the initial confining pressure is the most significant. The dilation gradient of path II is the largest, but the degree of dilatancy before the critical point is the smallest due to its susceptibility to fracture. The critical values of the dilatancy parameters for path III are the highest and are minimally affected by the initial confining pressure, indicating the most significant dilatancy properties. Establish the relationship between the deformation parameters and the crack-induced volumetric strain and define the damage variable accordingly. The critical damage state and the damage accumulation process under various stress paths were examined in detail. The results show that the damage evolution is obviously differentiated with the bifurcation of the stress paths, and three different types of damage curve clusters are formed, indicating that the damage accumulation path is highly dependent on the stress path. The research findings quantitatively reveal the differences in deformation response and damage characteristics of Beishan granite under varying stress paths, providing a foundation for studying the nonlinear mechanical behavior and damage failure mechanisms of hard brittle rock under complex loading conditions. Full article

Joining steel and Al alloys can fully utilize their advantages for both base metals (BMs) and optimize automobile structures. In this study, the laser welding–brazing technique was utilized to join DP780 steel and aluminum alloy 5754 (AA5754). The mechanical properties, microstructure, and fracture locations of steel–Al joints prepared using different laser spot positions were comparatively investigated. As the proportion of the laser spot on the steel BM increased from 50% to 90%, the tensile–shear strength of the steel–Al welded joint rose from 169 MPa to 241 MPa. Meanwhile, the fracture location of the joint shifted from the interface to the BM of the aluminum alloy. The change in the laser spot position could dramatically affect the interfacial microstructure and fracture mode of the steel–Al joint. When the proportion of the laser spot on the steel BM was relatively small (50%), the growth of intermetallic compounds (IMCs) was inhibited. The metallurgical bonding effect at the steel–Al interface was poor. In this case, the interfacial zone became the primary path for the crack propagation. Thus, interface failure became the dominant failure mode of the steel–Al joint. On the contrary, metallurgical bonding at the interface was remarkably improved as the proportion of the laser spot on the BM of the steel increased (to 90%). It was determined that the IMCs could effectively hinder the propagation of cracks along the interface. Eventually, the joint fractured in the Al alloy’s BM, resulting in a qualified steel–Al joint. Full article

This study develops a meso-structural modeling approach for asphalt mixtures by integrating computed tomography (CT) technology and the discrete element method (DEM), which accounts for the morphological characteristics of aggregates, asphalt mortar, and voids. The indirect tensile (IDT) tests of SMA-13 asphalt mixtures, a commonly used skeleton-type asphalt mixture for the surface course of asphalt pavements, were numerically simulated using CT-DEM. Through a comparative analysis of the load–displacement curve, the peak load, and the displacements corresponding to the maximum loads from the IDT tests, the accuracy of the simulation results was validated against the experimental results. Based on the simulation results of the IDT tests, the internal force transfer paths were obtained through post-processing, and the force chain system was identified. The crack propagation paths and failure mechanisms during the IDT tests were analyzed. The research results indicate that under the external load of the IDT test, there are primary force chains in both vertical and horizontal directions within the specimen. The interaction between these vertically and horizontally oriented force chains governs the fracture progression of the specimen. During IDT testing, the internal forces within the aggregate skeleton consistently exceed those within the mortar, while interfacial forces at aggregate–mortar contacts maintain intermediate values. Both the aggregate’s and mortar’s internal forces exhibit strong linear correlations with temperature, with the mortar’s internal forces showing a stronger linear relationship with external loading compared to those within the aggregate skeleton. The evolution of internal meso-cracks progresses through three distinct phases. The stable meso-crack growth phase initiates at 10% of the peak load, followed by the accelerated meso-crack growth phase commencing at the peak load. The fracture-affected zone during IDT testing extends symmetrically 20 mm laterally from the specimen centerline. Initial meso-cracks predominantly develop along aggregate–mortar interfaces and void boundaries, while subsequent propagation primarily occurs through interfacial zones near the main fracture path. The microcrack initiation threshold demonstrates dependence on the material’s strength and deformation capacity. Furthermore, the aggregate–mortar interfacial transition zone is a critical factor dominating crack resistance. Full article

This paper investigates the effects of Y content on the microstructure and mechanical properties of Mg-9Gd-xY-0.5Zr alloys. The mechanical properties, together with the grain size, first increase and then decrease, exhibiting a non-monotonous change with the increase in Y content. The alloy with 3 wt.% Y exhibits the best mechanical properties compared to the Y free alloy, with an increase in ultimate tensile strength and yield strength of 33.4% and 19.2%, respectively. However, further increase in the Y content (5 wt.%) does not enhance the strength but promotes the growth of the Mg₅(Gd,Y), becoming nucleation points and propagation paths for cracks, leading to a decrease in performance. The cubic phase REH₂ and oxide are not the reasons for the poor ductility in as-cast Mg-9Gd-xY-0.5Zr alloys due to low content, and the crystallographic orientation relationship between REH₂ and α-Mg is (220)_REH2//(11$\overline{2}$0)_Mg, and the interface mismatch is 9.13%. This paper systematically prepares and investigates the high-strength as-cast Mg-Gd-Y-Zr alloy, which has important guiding significance. Full article

The presence of mixed-mode stresses, combining both opening and shearing components, complicates fatigue life estimation when applying the Paris law. To address this, the crack path, along with Mode-I (opening) and Mode-II (shear) components, was numerically analyzed using Fracture Analysis Code (Franc2D) based on the linear elastic fracture mechanics (LEFM) approach. Accordingly, fatigue life and stress intensity factors (SIFs) under various biaxial loading ratios (λ) were calculated using the Paris law and compared with available data in the literature. The results show that crack growth is primarily driven by the Mode-I component, which exhibits the largest magnitude. Thus, the Mode-I stress intensity factor (K_I) was adopted for the numerical integration of the fatigue life equation. Furthermore, the influence of normal and transverse loads (σ_y and σ_x, respectively) on the crack path plane and SIF was examined for λ. The analysis revealed that lower λ values led to faster crack propagation, while higher λ values resulted in extended fatigue life due to an increased number of cycles to failure. The comparison demonstrated good agreement with reference data, confirming the reliability of the proposed modeling approach over a wide range of biaxial loading conditions. Full article

Ti-6Al-4V (Ti64) is widely used in the additive manufacturing (AM) industry for its superior mechanical properties; however, severe anisotropy is inevitable. In this work, a Ti64 sample fabricated using laser-directed energy deposition is used for fundamental investigations into the anisotropy of its microstructure, mechanical properties, and fracture behaviors. The microstructure of martensite α and prior β-Ti grains are characterized in both the XOY and XOZ planes. The tensile/compressive properties and microhardness along the building direction (BD) and scanning direction (SD) are tested, and it is found that the sample along the SD has better comprehensive mechanical properties. Due to grain boundary α (GB-α), different fracture behaviors and crack propagation paths are found along the BD and SD. When tensile force is parallel to the growth orientation of GB-α, a much higher density of microcracks caused by fractured GB-α is found to contribute to a prolonged elongation and the weakening of strength. While stretching along the SD, the cracks would propagate along the GB-α easily and straightly, which might lead to lower elongation. Full article

The high temperature performance of steel structures has long been a focus of research, but research on the damage and crack propagation mechanism of steel with initial defects at high temperature is relatively low. The high temperature performance of most steel structures in engineering has an important impact on the function and safety of the whole structure. At present, Peridynamics (PD) theory uses the integral method that has unique advantages compared with traditional methods to solve structural damage and fracture problems. Therefore, the effect of temperature change on steel properties is introduced into the PD, and the PD constitutive equation at high temperature is proposed. The damage and crack propagation mechanisms of 2D Q345 steel plates with bilateral cracks and different bolt holes at 20 °C, 300 °C, 400 °C and 600 °C were analyzed by applying temperature action and external load to double-cracked steel specimens by the direct thermostructural coupling method. At the same time, the damage values, displacement changes in X direction and Y direction under different temperatures were compared and analyzed, and the effects of temperature, bolt hole and external load on the damage, displacement and crack growth path of different parts of the structure were obtained. Full article

Since fan blades are exposed to fatigue, and in some cases harsh loading conditions, they may exhibit fracture failures due to crack propagation, resulting in significant losses. Previous studies of crack propagation in blades are mainly confined to either simplified blade geometry or loads, resulting in a significant discrepancy between the simulated crack propagation and the real blade propagation behavior, while it is lacking for challenging shapes and loads. A co-simulation approach of FRANC3D and ABAQUS was developed to study the crack propagation of an axial-flow fan blade subjected to centrifugal, aerodynamic, and combined loads. The projected approach is validated with results obtained from analytical calculations and experiments. Meanwhile, making use of benchmarks, the Stress Intensity Factor (SIF) and the prediction of mixed-mode crack growth path are validated. Considering various loads, the crack propagation path response for the fan blade is computed for different growth steps. The results pinpoint that the crack propagation length of the crack tip center is maximum under centrifugal loading. However, the aerodynamic load led to a maximum propagation length of the crack tip endpoints. In addition, the combined force of centrifugal and aerodynamic loads limits the crack from growing. Full article

The assessment of fatigue cracks is an elementary part of the design process of lightweight structures subject to operational loads. Although angled sheets are standard components in forming technology, fatigue crack growth in geometries like C- and L-sections has been little-studied and is mostly limited to crack growth before the transition through the corner. In this study, fatigue crack propagation is simulated to explore the influence of sheet thickness, corner angle and corner radius on the fatigue life in an L-section. The stress intensity factor (SIF) is derived as the driving force of crack growth over the full crack path. Special attention is paid to the evolution of the SIF in the radius sub-section and its implications on the fatigue life. The results show that the SIF in an angled sheet for given loading conditions and crack lengths cannot be readily approximated by the SIF in an equivalent straightened sheet. The bending angle and radius lead to crack growth retardation or acceleration effects. These findings are important for the design and optimization of forming geometries with regard to fatigue crack growth. Full article

A high-temperature, high-cycle fatigue test was conducted on a nickel-based single-crystal superalloy with a pore structure. Optical and scanning electron microscopy were utilized to examine the crack propagation paths and fatigue fracture surfaces at the macro and micro scales. The analysis of crack initiation and propagation related to the pore structure facilitated the development of a crack shape factor reflecting these distinct fracture behaviors. Predictions about the high-cycle fatigue stress experienced by the specimen were made, accompanied by an error analysis, providing critical insights for precise stress calculations and structural optimization in engine blade design. The results reveal that high-cycle fatigue cracks originate from corner cracks at pore edges, with the initial propagation displaying smooth crystallographic plane features. Subsequent stages show clear fatigue arc patterns in the propagation zones. The fracture surface exhibits the significant layering of oxide layers, primarily composed of NiO, with traces of CoO displaying columnar growth. AL₂O₃ is predominantly found at the interfaces between the matrix and oxide layers. Short and straight dislocations near the oxide layers and within the matrix suggest that dislocation multiplication and planar slip dominate the slip mechanisms in this alloy. The orientation of the fracture surface is mainly perpendicular to the load direction, with minor inclined facets in localized areas. Correlations were established between the plastic zone dimensions at the crack tips and the corresponding fatigue stresses. Without grain boundaries in single-crystal alloys, these dimensions are easily derived as parameters for fatigue stress analysis. The selected crack shape factor, “elliptical corner crack at pore edges”, captures the initiation and propagation traits relevant to porous structures. Subsequent calculations, accounting for the impact of oxide layers on stress assessments, indicated an error ratio ranging from 1.00 to 1.21 compared to nominal stress values. Full article

Numerical simulation of fatigue crack growth in welded joints is not well represented in the literature, especially from the point of view of material heterogeneity in a welded joint. Thus, several case studies are presented here, including some focusing on fracture, presented by two case studies of mismatched high-strength low-alloyed (HSLA) steel welded joints, with cracks in the heat affected zone (HAZ) or in weld metal (WM). For fatigue crack growth, the extended finite element method FEM (XFEM) was used, built in ABAQUS and ANSYS R19.2, as presented by four case studies, two of them without modelling different properties of the welded joint (WJ). In the first one, fatigue crack growth (FCG) in integral (welded) wing spar was simulated by XFEM to show that its path is partly along welded joints and provides a significantly longer fatigue life than riveted spars of the same geometry. In the second one, an integral skin-stringer panel, produced by means of laser beam welding (LBW), was analysed by XFEM in its usual form with stringers and additional welded clips. It was shown that the effect of the welded joint is not significant. In the remaining two papers, different zones in welded joints (base metal—BM, WM, and HAZ) were represented by different coefficients of the Paris law to simulate different resistances to FCG in the two cases; one welded joint was made of high-strength low-alloyed steel (P460NL1) and the other one of armour steel (Protac 500). Since neither ABAQUS nor ANSYS provide an option for defining different fatigue properties in different zones of the WJ, an innovative procedure was introduced and applied to simulate fatigue crack growth through different zones of the WJ and evaluate fatigue life more precisely than if the WJ is treated as a homogeneous material. Full article