Virtual reassembling of 3D fragments for the data-driven analysis of fracture mechanisms in composite materials

Abstract: This paper introduces a novel method for characterizing fracture mechanisms in composite materials using 3D image data gained by computed tomography (CT) measurements. In mineral liberation, the understanding of these mechanisms is crucial, particularly whether fractures occur along the boundaries of mineral phases (intergranular fracture) and/or within mineral phases (transgranular fracture). Conventional techniques for analyzing fracture mechanisms are focused on globally comparing the surface exposure of mineral phases extracted from image measurements before and after fracture. Instead, we present a virtual reassembling algorithm based on image registration techniques, which is applied to 3D data of composite materials before and after fracture in order to determine and characterize the individual fracture surfaces. This enables us to conduct a local quantitative analysis of fracture mechanisms by voxelwise comparing adjacent regions at fracture surfaces. A quantitative analysis of fracture mechanisms is especially important in the context of geometallurgical recycling processes. As primary deposits are decreasing worldwide, the focus is shifting to secondary raw materials containing low concentrations of valuable elements such as lithium. To extract these elements, they can be enriched as engineered artificial minerals in the slag phase of appropriately designed cooling processes. The subsequent liberation through comminution processes, such as crushing, is essential for the extraction of valuable minerals. A better understanding of crushing processes, especially fracture mechanisms in slags, is crucial for the success of recycling. The reassembling algorithm presented in this paper is evaluated through a simulation study, followed by an application to a naturally occurring ore and a slag resulting from a recycling process.