Statistical analysis of microstructurally small fatigue crack growth in three-dimensional polycrystals based on high-fidelity numerical simulations

Microstructurally small cracks (MSCs) are sensitive to their local microstructural neighborhoods, resulting in highly variable 3D crack propagation within individual samples and among population of samples. Statistically quantifying this complex spatiotemporal variability requires collecting and analyzing a large number of 3D MSC growth observations, which remains challenging due to experimental constraints that limit the availability of 3D observations of MSCs in the existing literature. We address this gap by leveraging virtual observations of MSC growth using a state-of-the-art, high-fidelity simulation framework to provide a statistical perspective on 3D MSC growth behavior. The MSC growth simulations were performed in 40 unique statistically similar polycrystalline microstructures, and the data extracted from the virtual observations were collectively analyzed to quantify variability in geometric, microstructural, and micromechanical aspects of MSCs. Variability in tortuosity, crack surface crystallography, and MSC growth parameters (local crack extension and kink angle) were quantified statistically. The results show that 3D MSC surfaces do not necessarily propagate along {111} crystallographic planes despite crack traces on radial planes being closely aligned with {111} slip plane traces. Also, the 3D MSC surfaces exhibit increasingly tortuous propagation and spatially varying local crack growth rates (with variability as high as 59% among the population). Moreover, correlation study revealed some of the highly influential microstructural and micromechanical features controlling MSC growth parameters. The quantified variability holds direct implications for advanced materials prognosis in engineering applications, and the identified features from the correlation study can be leveraged to train machine learning models for rapidly predicting MSC growth behavior in the future.