Meso-scale size effects of material heterogeneities on crack propagation in brittle solids: Perspectives from phase-field simulations

Brittle solids are often toughened by adding a second-phase material. This practice often results in composites with material heterogeneities on the meso scale: large compared to the scale of the fracture process zone but small compared to that of the application. The specific configuration (both geometrical and mechanical) of this mesoscale heterogeneity is generally recognized as important in controlling crack propagation behavior and, subsequently, the (effective) toughness of the composite. Here, we systematically investigate how dynamic brittle fracture navigates through a linear array of mesoscale inclusions. Using a variational phase-field (PF) approach, we compute the apparent crack speed and fracture energy dissipation rate to compare crack propagation (and the resulting toughening) under Mode-I loading for various configurations of inclusions. We identify an interplay between the size of inclusion and that of the K-dominant zone in the presence of elastic heterogeneity: matching these two sizes gives rise to the best toughening outcome for a given area fraction of inclusions. We discuss mechanisms that rationalize this observation and the importance of the length scale parameter used in PF models in interpreting simulation results. Our work sheds physical insight into the interaction between size effects and material properties, thereby opening a venue for the rational design of functional (architected) composites for dynamic fracture applications.