A Study of Microporosity-Tensile Strength Interaction Using Failure Plane Imaging

Abstract

This study investigates the correlation between microporosity characteristics and tensile strength in metal alloy specimens through advanced failure plane imaging techniques. Using high-resolution electron microscopy and 3D tomographic reconstruction, we quantified pore size distributions, spatial arrangements, and morphological features across 75 aluminum alloy specimens subjected to tensile testing until failure. Statistical analysis revealed a significant negative correlation (r = -0.87, p < 0.001) between total pore volume fraction and ultimate tensile strength, with pore size distribution heterogeneity emerging as a more reliable predictor of failure behavior than average porosity alone. Clustering analysis identified three distinct microporosity patterns associated with specific strength profiles. The novel aspect of our methodology lies in correlating these microstructural features directly with failure plane characteristics, demonstrating that pore alignment and interconnectivity along failure paths significantly impact tensile behavior. Our findings provide a quantitative framework for predicting mechanical properties based on microporosity characteristics, with potential applications in quality control, material design optimization, and computational modeling of failure mechanisms in lightweight structural components.