Abigail Hunter

Agnese Marcato, Aleksandra Pachalieva, Ryley G. Hill et al.

Accurately predicting when and how materials fail is critical to designing safe, reliable structures, mechanical systems, and engineered components that operate under stress. Yet, fracture behavior remains difficult to model across the diversity of materials, geometries, and loading conditions in real-world applications. While machine learning (ML) methods show promise, most models are trained on narrow datasets, lack robustness, and struggle to generalize. Meanwhile, physics-based simulators offer high-fidelity predictions but are fragmented across specialized methods and require substantial high-performance computing resources to explore the input space. To address these limitations, we present a data-driven foundation model for fracture prediction, a transformer-based architecture that operates across simulators, a wide range of materials (including plastic-bonded explosives, steel, aluminum, shale, and tungsten), and diverse loading conditions. The model supports both structured and unstructured meshes, combining them with large language model embeddings of textual input decks specifying material properties, boundary conditions, and solver settings. This multimodal input design enables flexible adaptation across simulation scenarios without changes to the model architecture. The trained model can be fine-tuned with minimal data on diverse downstream tasks, including time-to-failure estimation, modeling fracture evolution, and adapting to combined finite-discrete element method simulations. It also generalizes to unseen materials such as titanium and concrete, requiring as few as a single sample, dramatically reducing data needs compared to standard ML. Our results show that fracture prediction can be unified under a single model architecture, offering a scalable, extensible alternative to simulator-specific workflows.

M. K. Mudunuru, N. Panda, S. Karra et al.

In brittle fracture applications, failure paths, regions where the failure occurs and damage statistics, are some of the key quantities of interest (QoI). High-fidelity models for brittle failure that accurately predict these QoI exist but are highly computationally intensive, making them infeasible to incorporate in upscaling and uncertainty quantification frameworks. The goal of this paper is to provide a fast heuristic to reasonably estimate quantities such as failure path and damage in the process of brittle failure. Towards this goal, we first present a method to predict failure paths under tensile loading conditions and low-strain rates. The method uses a $k$-nearest neighbors algorithm built on fracture process zone theory, and identifies the set of all possible pre-existing cracks that are likely to join early to form a large crack. The method then identifies zone of failure and failure paths using weighted graphs algorithms. We compare these failure paths to those computed with a high-fidelity model called the Hybrid Optimization Software Simulation Suite (HOSS). A probabilistic evolution model for average damage in a system is also developed that is trained using 150 HOSS simulations and tested on 40 simulations. A non-parametric approach based on confidence intervals is used to determine the damage evolution over time along the dominant failure path. For upscaling, damage is the key QoI needed as an input by the continuum models. This needs to be informed accurately by the surrogate models for calculating effective modulii at continuum-scale. We show that for the proposed average damage evolution model, the prediction accuracy on the test data is more than 90\%. In terms of the computational time, the proposed models are $\approx \mathcal{O}(10^6)$ times faster compared to high-fidelity HOSS.

A. Hunter, B. A. Moore, M. K. Mudunuru et al.

In this paper, five different approaches for reduced-order modeling of brittle fracture in geomaterials, specifically concrete, are presented and compared. Four of the five methods rely on machine learning (ML) algorithms to approximate important aspects of the brittle fracture problem. In addition to the ML algorithms, each method incorporates different physics-based assumptions in order to reduce the computational complexity while maintaining the physics as much as possible. This work specifically focuses on using the ML approaches to model a 2D concrete sample under low strain rate pure tensile loading conditions with 20 preexisting cracks present. A high-fidelity finite element-discrete element model is used to both produce a training dataset of 150 simulations and an additional 35 simulations for validation. Results from the ML approaches are directly compared against the results from the high-fidelity model. Strengths and weaknesses of each approach are discussed and the most important conclusion is that a combination of physics-informed and data-driven features are necessary for emulating the physics of crack propagation, interaction and coalescence. All of the models presented here have runtimes that are orders of magnitude faster than the original high-fidelity model and pave the path for developing accurate reduced order models that could be used to inform larger length-scale models with important sub-scale physics that often cannot be accounted for due to computational cost.