A nonlinear analytical perspective on fracture behavior and crack growth in metallic materials

Articles in Press

Document Type : Research Paper

Author
Mohammad Sajjad Kiani
Department of Mechanical Engineering, Tehran University, Tehran, Iran
10.22075/ijnaa.2026.40194.5609
Abstract
Fracture behavior and fatigue crack growth in metallic materials are influenced by complex, nonlinear interactions among loading conditions, environmental factors, microstructure, residual stresses, and manufacturing processes. Classical fracture mechanics models, such as Linear Elastic Fracture Mechanics (LEFM) and the Paris law, often fail to capture these coupled effects under realistic service conditions. This study presents a systematic literature review (SLR) following the PRISMA 2020 guidelines to synthesize recent advances in understanding nonlinear fracture responses in metals. A reproducible search across major databases (ScienceDirect, SpringerLink, Wiley, Scopus, and Google Scholar) from 2010 to 2025 yielded 54 high-quality studies after rigorous screening. Selected works were classified by material type, loading mode, environmental conditions, microstructural features, and modelling approaches. The analysis highlights that separable assumptions in conventional models are inadequate for describing coupled thermal-mechanical, environmental, and microstructural effects, particularly in advanced materials like additively manufactured alloys and welded high-strength steels. Key findings reveal recurring patterns of crack growth acceleration due to hydrogen embrittlement, variable-amplitude loading, and residual stresses, alongside significant gaps in multi-factor interaction studies and short-crack behavior under realistic conditions. A novel conceptual framework is proposed that integrates these factors through an effective crack-tip driving force ($\Delta k_{\text{eff}}$), providing a mechanistic basis for improved predictive modelling. This framework offers a structured nonlinear perspective to guide future experimental, numerical, and multi-scale modelling efforts in fracture mechanics of metallic materials.
Keywords
Fatigue crack growth
Fracture mechanics
Systematic literature review
Nonlinear interactions
Microstructural heterogeneity
Effective driving force
Conceptual framework
[1] A.M. Alshoaibi, Computational simulation of 3D fatigue crack growth under mixed-mode loading, Appl. Sci. 11 (2021), no. 13, 5953.
[2] A.M. Alshoaibi and S.H. Advani, Fatigue crack growth under mixed-mode, Appl. Sci. 13 (2023), no. 16, 9446.
[3] F.V. Antunes, Fatigue crack growth in metallic materials, Materials 16 (2023), no. 1, 11.
[4] F.V. Antunes, R. Branco, and P. Prates, Fatigue crack growth in metallic materials, Materials 16 (2023), no. 1, 11.
[5] P. Foti, N. Razavi, A. Fatemi, and F. Berto, Multiaxial fatigue in AM components, Prog. Mater. Sci. 137 (2023), 101126.
[6] L. Gu, M. Li, T. Zhang, and G. Li, Fatigue crack propagation test and numerical simulation analysis of B780CF steel, Front. Mater. 12 (2025), 1593388.
[7] A. Hohenwarter, T. Leitner, and R. Pippan, Fatigue crack propagation across multiple length scales in metallic materials, Annu. Rev. Mater. Res. 54 (2024), 223–246.
[8] H. Javidrad, B. Koc, H. Bayraktar, U. Simsek, and K. Gunaydin, Fatigue performance of metal additive manufacturing: A comprehensive overview, Virtual Phys. Prototyp. 19 (2024), no. 1, e2302556.
[9] Y.A. Kedir and H.G. Lemu, Prediction of fatigue crack initiation: Review, Metals 13 (2023), no. 3, 487.
[10] J. Kraft, A. Linn, M. Wächter, A. Ederts, and M. Vormwald, Multiaxial fatigue behavior in steel and cast iron, Int. J. Fatigue 183 (2024), 108259.
[11] Y. Liu, J. Chen, Z. Sun, H. Zhang, and Q. Yuan, Fatigue crack closure in titanium alloy, Metals 13 (2023), no. 8, 1377.
[12] A.H.I. Mourad, S. Sajith, S. Shitole, A. Almomani, S.H. Khan, A. Elsheikh, and A.K. Alzo'ubi, Fatigue life and crack growth prediction of metallic structures: A review, Structures 76 (2025), 109031.
[13] P.C. Paris and F. Erdogan, A critical analysis of crack propagation laws, J. Basic Eng. 85 (1963), no. 4, 528–534.
[14] R.O. Ritchie, Mechanisms of fatigue-crack propagation in ductile and brittle solids, Int. J. Fract. 100 (1999), 55–83.
[15] D. Rozumek, Fracture mechanics and fatigue design in metallic materials, Metals 11 (2021), no. 12, 1957.
[16] N. Sanaei and A. Fatemi, Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review, Prog. Mater. Sci. 117 (2021), 100724.
[17] M.D. Sangid, The physics of fatigue crack propagation, Int. J. Fatigue 197 (2025), 108928.
[18] T.K. Shoemaker, Z. Harris, C. Smudde, and M.R. Hill, Three-dimensional fatigue crack path in 17-4PH stainless steel, Int. J. Fatigue 175 (2023), 107735.
[19] W. Song, Z. Man, J. Xu, X. Wang, C. Liu, G. Zhou, and F. Berto, Fatigue crack growth in overmatched welded joint of D32 steel, Metals 13 (2023), no. 3, 535.
[20] T. Strohmann, D. Melching, F. Paysan, E. Dietrich, G. Requena, and E. Breitbarth, Next generation fatigue crack growth experiments of aerospace materials, Sci. Rep. 14 (2024), 14075.
[21] Q. Zhu, P. Zhang, X. Peng, and L. Yan, Fatigue crack growth behavior and fracture toughness of EH36 TMCP steel, Materials 14 (2021), no. 21, 6621.
 
 
International Journal of Nonlinear Analysis and Applications

Articles in Press, Corrected Proof
Available Online from 15 November 2026

  • Receive Date 28 November 2025
  • Revise Date 02 January 2026
  • Accept Date 02 January 2026