Phase-field modeling of thermal shock-induced fracture in layered materials

Thermally induced failure of layered materials, particularly chrome-plated calendering rollers, represents a critical challenge limiting reliable high-temperature industrial applications. Such thermally induced fracture behaviors are governed by multi-physical field coupling effects among material properties, geometric configurations, and thermal boundary conditions. However, the sensitivity mechanisms of these key parameters have not been systematically quantified, leading to a lack of universal theoretical support for crack-resistant design.To address this challenge, this study establishes a unified thermo-mechanical phase-field model, enabling multi-parameter coupled analysis of thermally induced crack nucleation and growth in layered systems. The model quantitatively reveals how geometric dimensions and material property ratios control cracking mechanisms, providing predictive capabilities for coating performance and structural optimization in industrial applications. The highlights of the article are summarized as follows:1. Developed a robust thermo-mechanical phase-field model for layered material fracture analysis, demonstrating high adaptability and predictive accuracy.2. Revealed quantitative relationships between chrome layer thermal resistance and structural parameters, offering theoretical support for optimization design.3. Systematically quantified the influence mechanisms of material property ratios on critical crack initiation temperatures in layered systems.4. Clarified the dependency of crack initiation sites on material attributes, providing a theoretical basis for crack control and structural optimization.