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A new metric was developed to quantify the impact of surface-connected defects and internal pores of different morphologies, namely irregular lack of fusion (LoF) pores and spherical keyhole pores, on the mechanical properties and fracture location of AlSi10Mg tensile samples fabricated using laser powder bed fusion additive manufacturing. As defect volume alone has been shown to be insufficient to predict fracture location, the proposed defect impact metric (DIM) incorporates contributions from additional defect features, including proximity to the surface, interaction with neighboring defects, morphology, and reduction in load-bearing cross-sectional area to better assess a defect’s propensity for corresponding to fracture location. The fracture location of keyhole samples was captured by large surface-connected defects with numerous neighboring defects and resulted in increased losses in load-bearing area. In contrast, LoF samples fractured at regions with either large surface-connected defects or large internal pores with many defects in close proximity, high curvatures, and large projected areas. The proposed DIM outperformed existing defect-based frameworks in identifying fracture locations in both LoF and keyhole samples by incorporating surface roughness, defect projected area, and interactions between defects based on distance, volume, and configuration. Additionally, the maximum DIM value within the fracture range was more strongly correlated to strength and ductility than porosity or defect size for LoF samples, demonstrating the potential of the DIM to non-destructively assess the effects of defects on mechanical behavior. The broader applicability of the DIM framework was demonstrated in its ability to capture fracture in both PBF-LB AlSi10Mg and Alloy 718.
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This content will become publicly available on March 3, 2027
Extraordinarily high fractocohesive lengths in polymer-like networks
The failure resistance of polymer networks dictates their utility as material candidates across industries. However, relating the key length scales driving crack growth to molecular mechanisms remains a key bottleneck in predicting and designing against fracture. The fractocohesive length—defined in terms of the ratio of fracture energy to the specific work to rupture—of a material correlates with the length scale of energy dissipation and controls fracture resistance. Although the Lake–Thomas model predicts the fractocohesive length of a perfect polymer network to match the undeformed mesh size, real soft materials exhibit values that far exceed this prediction. Here, we report extraordinarily high fractocohesive lengths in polymer-like networks with and without defects. We find that even perfect networks can have fractocohesive lengths orders of magnitude higher than the undeformed mesh size due to highly nonlinear chain behavior giving rise to nonlocal effects during fracture. Introducing defects further increases the fractocohesive length. We identify quantitative relations between nonlinear chain mechanics, defect length, defect density, and fractocohesive length. Overall, strain-stiffening chain behavior, defect density, and defect size independently correlate with larger fractocohesive lengths in polymer-like networks, and their individual effects can be collapsed into a single power law scaling. These outcomes point the way towards improved physics-informed design of soft yet tough polymers and metamaterials.
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- Award ID(s):
- 2430106
- PAR ID:
- 10712177
- Publisher / Repository:
- Sage Journals
- Date Published:
- Journal Name:
- Mathematics and Mechanics of Solids
- ISSN:
- 1081-2865
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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