Experimental Analysis of Fracture Mechanics of Aluminum 7075 Alloy Plate With an Edge Crack Using MATLAB Software

Fracture mechanics investigates the behavior of materials containing cracks under applied loads, particularly in high‐strength aluminum alloys such as AA7075 used in aerospace and automotive structures. This study evaluates the fracture behavior of AA7075‐T6 through experimental testing, finite element analysis (FEA), and boundary element techniques (BET). A standard single‐edge‐notched (SEN) specimen with dimensions W = 50 mm, B = 5 mm, and an initial crack length a 0 = 10 mm was modeled and tested under uniaxial tensile loading of σ = 200 MPa. The FEA predicted a Mode I stress intensity factor of K 1 = 18.2 MPa√m and an energy release rate of G 1 = 82.5 J/m 2 , indicating predominantly brittle behavior consistent with AA7075‐T6. BET simulations showed stable crack growth up to a critical crack length of a c = 18.4 mm, after which unstable fracture occurred. The predicted fracture toughness K I C = 25.6 MPa√m aligns with published values for AA7075‐T6. Fatigue modeling using Paris’ Law ( C = 1.2 × 10 −10 , m = 3.5) produced crack‐growth rates between 10 −6 and 5 × 10 −4 mm/cycle for Δ K values of 10–20 MPa√m. MATLAB computed stress intensity factor, energy release rate and crack‐growth relationships using analytical linear elastic fracture mechanics equations and specimen‐specific parameters. The results confirm that crack growth in AA7075 is strongly dependent on crack length, geometry, and applied stress. The findings provide reliable estimates of crack progression in AA7075 components. It is recommended that service stresses remain below 70% of the alloy’s yield strength to prevent premature crack propagation and extend structural lifespan.