The phase field fracture method has emerged as a promising computational tool for modelling a variety of problems including, since recently, hydrogen embrittlement and stress corrosion cracking. In this work, we demonstrate the potential of phase field-based multi-physics models in transforming the engineering assessment and design of structural components in hydrogen-containing environments. First, we present a theoretical and numerical framework coupling deformation, diffusion and fracture, which accounts for inertia effects.Several constitutive choices are considered for the crack density function, including choices with and without an elastic phase in the damage response. The material toughness is defined as a function of the hydrogen content using an atomistically-informed hydrogen degradation law. The model is numerically implemented in 2D and 3D using the finite element method. The resulting computational framework is used to address a number of case studies of particular engineering interest. These are intended to showcase the model capabilities in: (i) capturing complex fracture phenomena, such as dynamic crack branching or void-crack interactions, (ii) simulating standardised tests for critical components, such as bolts, and (iii) enabling simulation-based paradigms such as Virtual Testing or Digital Twins by coupling model predictions with inspection data of large-scale engineering components. The evolution of defects under in-service conditions can be predicted, up to the ultimate failure. By reproducing the precise geometry of the defects, as opposed to re-characterising them as sharp cracks, phase field modelling enables more realistic and effective structural integrity assessments.
We present a new mechanistic, phase field-based formulation for predicting hydrogen embrittlement. The multi-physics model developed incorporates, for the first time, a Taylor-based dislocation model to resolve the mechanics of crack tip deformation. This enables capturing the role of dislocation hardening mechanisms in elevating the tensile stress, hydrogen concentration and dislocation trap density within tens of microns ahead of the crack tip. The constitutive strain gradient plasticity model employed is coupled to a phase field formulation, to simulate the fracture process, and to a multi-…
We present a combined phase field and cohesive zone formulation for hydrogen embrittlement that resolves the polycrystalline microstructure of metals. Unlike previous studies, our deformation-diffusion-fracture modelling framework accounts for hydrogen-microstructure interactions and explicitly captures the interplay between bulk (transgranular) fracture and intergranular fracture, with the latter being facilitated by hydrogen through mechanisms such as grain boundary decohesion. We demonstrate the potential of the theoretical and computational formulation presented by simulating inter- and tr…
We present a gradient-based theoretical framework for predicting hydrogen assisted fracture in elastic-plastic solids. The novelty of the model lies in the combination of: (i) stress-assisted diffusion of solute species, (ii) strain gradient plasticity, and (iii) a hydrogen-sensitive phase field fracture formulation, inspired by first principles calculations. The theoretical model is numerically implemented using a mixed finite element formulation and several boundary value problems are addressed to gain physical insight and showcase model predictions. The results reveal the critical role of p…
A generalised framework for phase field-based modelling of coupled problems: application to thermo-mechanical fracture, hydraulic fracture, hydrogen embrittlement and corrosion
We investigate the influence of microstructural traps in hydrogen-assisted fatigue crack growth. To this end, a new formulation combining multi-trap stress-assisted diffusion, mechanism-based strain gradient plasticity and a hydrogen- and fatigue-dependent cohesive zone model is presented and numerically implemented. The results show that the ratio of loading frequency to effective diffusivity governs fatigue crack growth behaviour. Increasing the density of \emph{beneficial} traps, not involved in the fracture process, results in lower fatigue crack growth rates. The combinations of loading f…
We investigate the influence of microstructural traps on hydrogen diffusion and embrittlement in the presence of cyclic loads. A mechanistic, multi-trap model for hydrogen transport is developed, implemented into a finite element framework, and used to capture the variation of crack tip lattice and trapped hydrogen concentrations as a function of the loading frequency, the trap binding energies and the trap densities. We show that the maximum value attained by the lattice hydrogen concentration during the cyclic analysis exhibits a notable sensitivity to the ratio between the loading frequency…
Two-dimensional (2D) materials have many promising applications, but their scalable production remains challenging. Herein, we develop a glue-assisted grinding exfoliation (GAGE) method in which the adhesive polymer acts as a glue to massively produce 2D materials with large lateral sizes, high quality, and high yield. Density functional theory simulation shows that the exfoliation mechanism involves the competition between the binding energy of selected polymers and the 2D materials which is larger than the exfoliation energy of the layered materials. Taking h-BN as an example, the GAGE produ…
We present a phase field-based electro-chemo-mechanical formulation for modelling mechanics-enhanced corrosion and hydrogen-assisted cracking in elastic-plastic solids. A multi-phase-field approach is used to present, for the first time, a general framework for stress corrosion cracking, incorporating both anodic dissolution and hydrogen embrittlement mechanisms. We numerically implement our theory using the finite element method and defining as primary kinematic variables the displacement components, the phase field corrosion order parameter, the metal ion concentration, the phase field fract…
Heterostructures of wurtzite based devices have attracted great research interests since the tremendous success of GaN in light emitting diodes (LED) industry. Among the possible heterostructure material candidates, high quality GaN thin films on inexpensive and lattice matched ZnO substrate are both commercially and technologically desirable. However, the energy of ZnO polar surfaces is much lower than that of GaN polar surfaces. Therefore, the intrinsic wetting condition forbids such heterostructures. As a result, poor crystal quality and 3D growth mode were obtained. To dramatically change …
Atomic layer deposition (ALD) is a key technique for the continued scaling of semiconductor devices, which increasingly relies on reproducible and scalable processes for interface manipulation of 3D structured surfaces on the atomic scale. While ALD allows the synthesis of conformal films at low temperature with utmost control over the thickness, atomically-defined closed coatings and surface modifications are still extremely difficult to achieve because of three-dimensional growth during nucleation. Here, we present a route towards sub-nanometer thin and continuous aluminum oxide (AlOx) coati…
Unlike Si, 2-dimensional (2D) Transition Metal Dichalcogenides (TMDs) offer atomically thin channels for carrier transport in FETs. Despite advantages like superior gate control, steep sub-threshold swing and high carrier mobility offered by 2D FET channels, process related challenges like lack of selective doping techniques like implantation and CMOS compatible process for fabrication of 2D TMD based FETs hinder the anticipated viability of 2D semiconductor technology for future electronic applications. In this letter, we demonstrate a process oriented approach to realize superior ambipolarit…
