Numerical fracture analysis of alumina-based multi-materials: J-Integral evaluation and interfacial optimization in Al ₂ O ₃ /Ni/Al ₂ O ₃ and Al ₂ O ₃ /Cu–Ni–Cu/Al ₂ O ₃ systems

This study aims to investigate the fracture behavior and interfacial optimization of alumina-based multi-material systems, specifically Al2O3/Ni/Al2O3 and Al2O3/Cu/Ni/Cu/Al2O3, using finite element analysis (FEA) with ABAQUS. The research focuses on evaluating the stress distribution and fracture resistance of these configurations under thermomechanical loading. The study uses the J-integral method to quantify fracture toughness, considering the effect of cracks and defects at the interface. A three-dimensional finite element model was developed for both configurations, analyzing stress concentrations, fracture resistance, and crack propagation under various loading conditions. The results show that the Al2O3/Ni/Al2O3 system exhibits significant stress concentrations at the interface, leading to higher fracture susceptibility, especially under tensile loading. In contrast, the Al2O3/Cu/Ni/Cu/Al2O3 multilayer system demonstrates improved fracture resistance, with copper interlayers effectively reducing stress concentrations and enhancing energy dissipation. The J-integral values for the multilayer system are consistently lower, indicating greater fracture resistance and tolerance to defects. The study concludes that the introduction of copper interlayers significantly improves the mechanical performance of ceramic-metal assemblies, making them more suitable for high-temperature and high-stress applications. Based on these findings, it is recommended to optimize interlayer architecture in metal-ceramic joints to enhance durability and reliability in engineering applications.