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Acta Metall Sin  2026, Vol. 62 Issue (9): 1606-1614    DOI: 10.11900/0412.1961.2024.00302
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Multi-Scale Fatigue Crack Propagation Prediction Based on the Dual Drive of Random Forest Algorithm and Data Augmentation Strategy
DIAO Shengxuan, XIAO Jinyong, CHEN Yongbao, SHAN Kangzhong, YANG Jie()
Shanghai Key Laboratory of Multiphase Flow and Heat Transfer in Power Engineering, School of Energy and Power Engineering, University of Shanghai for Science and Technology, Shanghai 200093, China
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DIAO Shengxuan, XIAO Jinyong, CHEN Yongbao, SHAN Kangzhong, YANG Jie. Multi-Scale Fatigue Crack Propagation Prediction Based on the Dual Drive of Random Forest Algorithm and Data Augmentation Strategy. Acta Metall Sin, 2026, 62(9): 1606-1614.

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Abstract  

Data-driven methods based on machine learning have been employed to predict fatigue crack propagation. However, existing studies have largely overlooked the multi-scale nature of this process. Relying solely on macroscopic data for long-crack prediction often fails to capture the complete crack growth process, potentially resulting in non-conservative predictions. Moreover, purely data-driven models often lack interpretability, exhibit limited generalization capabilities, and struggle to adhere to physical laws. The challenge of integrating modeling with reasonable interpretations, driven by both data and mechanisms, remains a significant issue for researchers. In this study, we selected 304 austenitic stainless steel as the research object. To identify the algorithm with the best predictive performance, firstly, the fatigue crack propagation prediction capabilities of three algorithms were compared: K-nearest neighbor (KNN), support vector machine regression (SVR), and random forest (RF). The most effective algorithm and implemented data augmentation strategies based on three fatigue crack propagation models were selected, namely, long cracks, short cracks, and multi-scale cracks, to enhance prediction accuracy. Finally, using a dual-drive model framework that incorporated the data augmentation strategy, predictions of multi-scale fatigue crack propagation under different loads were conducted. Compared to the SVR and KNN algorithms, the results indicated that the RF algorithm had a lower root mean square error (RMSE) value and higher coefficient of determination (R2), making it more suitable for predicting fatigue crack propagation. Under a load of 370 MPa, the prediction accuracy for the training set ranked in the order of RF > KNN > SVR. By contrast, the accuracy for the test set was in the order of RF > SVR > KNN. The multi-scale fatigue crack propagation model effectively captured the entire process of crack growth, whereas the long- and short-crack models accurately represented only parts of it. Data enhancement based on the multi-scale crack model demonstrated significantly better results than the other two models, with increases in accuracy of 25.76% and 71.74% for the training and test sets, respectively. The dual-drive model based on the RF algorithm and data enhancement strategy exhibited strong generalization capabilities. Under a load of 350 MPa, the RMSE values for the training and test sets were 0.046 and 0.111, respectively, and R2 reached 0.995 and 0.961. Under a load of 330 MPa, the RMSE values for the training and test sets were 0.171 and 0.081, respectively, and the R2 reached 0.911 and 0.721. Finally, compared with the pure data-driven model based on the RF algorithm, the predictions from the dual-drive model were found to be significantly more accurate.

Key words:  multi-scale fatigue crack propagation      random forest algorithm      data augmentation strategy      dual drive model     
Received:  28 August 2024     
ZTFLH:  TG111.8  
Fund: National Natural Science Foundation of China(52375154);National Natural Science Foundation of China(52311530067)
Corresponding Authors:  YANG Jie, professor, Tel: (021)55272320, E-mail: yangjie@usst.edu.cn

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2024.00302     OR     https://www.ams.org.cn/EN/Y2026/V62/I9/1606

Fig.1  Multi-scale fatigue crack propagation test data of 304 stainless steel under different stress levels[9] (a—crack length, N—number of cycles; LC—long crack, PSC—physically small crack, MSC—microstructurally small crack)
Fig.2  Processes of data training and testing
Fig.3  Process of data augmentation
ModelParameterValue
Long crackC1.615 × 10-10
m2.58
Short crackA1.000 × 10-10.49
B1.19
Multi-scale crackC3.630 × 10-10
q1.37
Table 1  Parameters in the three fatigue crack propagation models[36]

Load / MPa

Number of experimental datasetNumber of data augmentation dataset
3306118
3505015
3704514
Table 2  Numbers of datasets
Fig.4  Comparisons of training results of training sets (a) and prediction results of testing sets (b) for three algorithms (SVR—support vector machine regression, KNN—nearest neighbor regression, RF—random forest regression, apre—predicted crack length, aexp—experimental crack length)
Fig.5  Comparisons of root mean square errors (RMSE) and coefficient of determinations (R2) among the three algorithms
Fig.6  Data augmentation effects of three fatigue crack propagation models on training results of training sets (a) and prediction results of test sets (b)
Fig.8  Comparison of RMSE and R2 after data augmentation based on the three models
Fig.8  Prediction results of multi-scale fatigue crack propagation at 350 MPa based on dual-drive model and RF model
(a) training results of training sets (b) prediction results of testing sets
Fig.9  Prediction results of multi-scale fatigue crack propagation at 330 MPa based on dual-drive model and RF model
(a) training results of training sets (b) prediction results of testing sets
Fig.10  RMSE and R2 at 350 and 330 MPa based on dual-drive model and RF model
(a) training results of training sets (b) prediction results of testing sets
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