Discrete‐Continuum Duality of Architected Materials: Failure, Flaws, and Fracture

Abstract

3D nano‐ and micro‐architected materials are resilient under compression; their susceptibility to flaws and fracture remain unexplored. This work reports the fabrication and tensile‐to‐failure response of hollow alumina nanolattices arranged into 5 µm octet‐truss unit cells. Some specimens contained through‐thickness center notches oriented at different angles to the loading direction, with a length‐over‐sample‐width ratio of 0.45. In situ tensile experiments reveal that for all orientations, failure initiates at the notch root, followed by instantaneous crack propagation along lattice planes orthogonal to extension. A tensile strength of 27.4 ± 0.7 MPa is highest for unnotched samples and decreases as notch orientation varies from 0° to 90° to its minimum, 7.2 ± 0.4 MPa; their specific tensile strength is ≈4 × higher than that for all other low‐density materials. Finite element simulations reproduce observed strengths and failure mechanisms: initial cracks always initiate at the nodal junctions with highest stress concentrations by tearing of alumina walls at the nodes. Subsequent crack propagation shifts maximum stress concentration to the nodes along lattice plane orthogonal to the loading direction. A modified analytical fracture model based on the effective notch length predicts tensile strengths consistent with experiments. These findings imply that continuum fracture mechanics can predict failure in nano‐architected materials, which helps develop advanced materials through informed architectural design.