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1. Structural fatigue and fracture of shape memory alloy actuators: Current status and perspectives

   https://doi.org/10.1177/1045389X211057216  

   Hasan, Md Mehedi; Baxevanis, Theocharis (July 2022, Journal of Intelligent Material Systems and Structures)

   Shape Memory Alloy (SMA)-actuators are efficient, simple, and robust alternatives to conventional actuators when a small volume and/or large force and stroke are required. The analysis of their failure response is critical for their design in order to achieve optimum functionality and performance. Here, (i) the existing knowledge base on the fatigue and overload fracture response of SMAs under actuation loading is reviewed regarding the failure micromechanisms, empirical relations for actuation fatigue life prediction, experimental measurements of fracture toughness and fatigue crack growth rates, and numerical investigations of toughness properties and (ii) future developments required to expand the acquired knowledge, enhance the current understanding, and ultimately enable commercial applications of SMA-actuators are discussed. 

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2. Plasticity Bridges Microscale Martensitic Shear Bands in Superelastic Nitinol

   https://doi.org/10.1007/s11340-025-01161-6  

   Christison, A.; Paranjape, H_M; Daly, S. (February 2025, Experimental Mechanics)

   Abstract BackgroundSuperelastic shape memory alloys (SMAs) such as nickel-titanium, also known as Nitinol, recover large deformations via a reversible, stress-induced martensitic transformation. ObjectivePartitioning the deformation into the contributions from superelasticity and plasticity and quantifying the interaction between these mechanisms is key to modeling their fatigue behavior. MethodsWe capture these microscopic interactions across many grains using a combination of scanning electron microscopy digital image correlation (SEM-DIC) and electron backscatter diffraction (EBSD). Modeling our data as a statistical distribution, we employ a Gaussian Mixture Model (GMM) soft clustering framework to understand how these mechanisms interact and evolve as a function of global strain. ResultsOur findings show that, under globally-applied uniaxial tensile loading, plasticity bridges deformation in regions where competing positive and negative martensitic shear bands intersect. Early stage transformation-induced plasticity is concentrated at these intersections and forms concurrently with the Lüders-like martensitic transformation front, often appearing with a zig-zag pattern that is linked to compound twinning at the martensite-martensite interface. At higher strains, austenite slip is activated as a second mechanism of plastic deformation. ConclusionsWe propose that this plastic bridging mechanism underpins the prestrain effects previously reported in the literature, where higher prestrains can enhance the fatigue strength of superelastic materials within a given loading mode. 

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3. Fracture toughness and fatigue crack growth resistance of precipitate-free and precipitation hardened NiTiHf shape memory alloys

   https://doi.org/10.1016/j.msea.2024.146443  

   Young, Benjamin; Orrostieta, Roberto; Haghgouyan, Behrouz; Lagoudas, Dimitris C; Baxevanis, T; Karaman, Ibrahim (May 2024, Materials Science and Engineering: A)

   The present work investigates fracture toughness, and actuation and mechanical fatigue crack growth responses of Ni50.3Ti29.7Hf20 HTSMAs across martensitic transformation with two different microstructures, one with H-phase nanoprecipitates and one without. H-phase precipitation is known to stabilize the actuation cycling response of NiTiHf HTSMAs and notably impacts transformation-induced plasticity. The fracture toughness tests performed reveal that precipitate-free NiTiHf has a higher fracture toughness and undergoes significantly more inelastic deformation than the one with the precipitates resulting in toughness enhancement, i.e., stable crack advance during fracture toughness experiments, which is not observed in the precipitated NiTiHf for the crack configuration and loading conditions tested. Furthermore, the precipitate free NiTiHf has higher actuation and mechanical fatigue crack growth resistance than the precipitation-hardened microstructure. This is attributed to plasticity buildup, which exacerbates the manifestation of retained martensite upon repeated transformations. The fatigue crack growth rates obtained from both actuation and mechanical fatigue experiments align to a single Paris Law Curve for the precipitation-hardened NiTiHf. This work aims to determine if unified Paris Law curves can be generated from mechanical and actuation fatigue experiments, irrespective of composition and microstructure, to estimate actuation fatigue crack growth rates, laborious and challenging to measure, from easier to detect mechanical fatigue crack growth rates. 

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4. Statistical mechanics of dislocation pileups in two dimensions

   https://doi.org/10.1103/PhysRevE.103.022139  

   Zhang, Grace H.; Nelson, David R. (February 2021, Physical Review E)

   Polyurethane (PU) elastomers are among the most used rubberlike materials due to their combined merits, including high abrasion resistance, excellent mechanical properties, biocompatibility, and good processing performance. A PU elastomer exhibits pronounced hysteresis, leading to a high toughness on the order of 104 J/m2. However, toughness gained from hysteresis is ineffective to resist crack growth under cyclic load, causing a fatigue threshold below 100 J/m2. Here we report a fatigue-resistant PU fiber–matrix composite, using commercially available Spandex as the fibers and PU elastomer as the matrix. The Spandex fibers are stiff, strong, and stretchable. The matrix is soft, tough, and stretchable. We describe a pullout test to measure the adhesion toughness between the fiber and matrix. The test is highly reproducible, showing an adhesion toughness of 3170 J/m2. The composite shows a maximum stretchability of 6.0, a toughness of 16.7 kJ/m2, and a fatigue threshold of 3900 J/m2. When a composite with a precut crack is stretched, the soft matrix causes the crack tip to blunt greatly, which distributes high stress over a long segment of the Spandex fiber ahead the crack tip. This deconcentration of stress makes the composite resist the growth of cracks under monotonic and cyclic loads. The PU elastomer composites open doors for realistic applications of fatigue-resistant elastomers 

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5. Molecular simulation of subcritical crack growth under dry conditions in a model brittle glass

   https://doi.org/10.1063/5.0285814  

   Deng, Binghui; Basu, Swastik; Huang, Liping; Shi, Yunfeng (September 2025, Journal of Applied Physics)

   Subcritical crack growth can occur under a constant applied load below the threshold value for catastrophic failure, also known as static fatigue. Here, we report how a crack grows under a combination of stress-intensity factor (K) and temperature in a model brittle glass using molecular dynamics simulations. The model glass is under dry conditions, thus avoiding the complexity of corrosion chemistry. The crack growth rate is shown to be inconsistent with the commonly used subcritical crack growth model rooted in the transition state theory (TST), in which the applied stress-intensity factor reduces the transition barrier. A new subcritical crack growth model is proposed with a constant barrier and a K-dependent prefactor in TST, representing the size of the region for potential bond breaking. The thermomechanical condition for subcritical crack growth is also mapped in the K-T domain, in between elastic deformation and catastrophic fracture regimes. Finally, we show substantial crack self-healing once the applied load is removed, under the thermodynamic driving force of surface energy reduction. Our findings provide new insights into the mechanochemical coupling during static fatigue and call for experimental investigation of whether the activation energy is K-dependent. 

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