机器学习在金属服役损伤与寿命预测中的应用

Applications of Machine Learning in Service-Induced Damage and Life Prediction of Metallic Materials

  • 摘要: 金属材料广泛应用于能源、航空、海洋等关键工程与装备制造,服役过程中受载荷、温度、压力及介质等多因素交互作用,易诱发腐蚀、疲劳、蠕变及其耦合损伤,进而威胁结构的完整性和服役安全。传统经验公式与物理模型在处理多源、高维及非线性数据时存在固有局限,难以满足复杂工况下材料服役损伤识别与寿命预测的实际需求,机器学习凭借其强大的数据处理能力,为此类问题提供了有效解决途径。本文围绕金属服役损伤演化与寿命预测,系统综述了机器学习方法的建模流程、技术策略与典型应用。以数据驱动建模的一般流程为切入点,在梳理传统机器学习算法、物理信息融合、迁移学习、增量学习及集成学习等技术策略的基础上,进一步综述了机器学习在腐蚀、疲劳、蠕变及多损伤耦合问题中的应用与研究进展,归纳了数据缺失、模型泛化不足与可解释性局限等关键挑战,进而从多源数据体系构建、物理机制约束与动态损伤预测等方面进行了展望。

     

    Abstract: Metallic materials are widely used in energy engineering, aerospace, marine engineering, and the manufacturing of critical equipment. During long-term service, metallic components are subjected to coupled effects of mechanical loading, temperature, pressure, corrosive media, and other environmental factors. These coupled service conditions can induce corrosion, fatigue, creep, and coupled damage, which may reduce structural integrity and threaten service safety. Accurate assessment of service-induced damage and reliable life prediction are therefore essential for the safe operation, maintenance planning, and life-cycle management of metallic components. Traditional empirical formulas and physics-based models have been widely used for corrosion rate estimation, fatigue life prediction, crack growth analysis, and creep rupture assessment. However, their applications are often limited when the damage process involves multi-source data, high-dimensional variables, nonlinear relationships, and extrapolation under complex service conditions. In this context, machine learning provides a data-driven approach for extracting hidden correlations from complex service data and establishing relationships among material characteristics, environmental conditions, loading parameters, damage features, and life-related indicators. This review focuses on machine learning methods for service-induced damage evolution and life prediction of metallic materials. First, the general workflow of data-driven modeling is summarized, including data acquisition, data preprocessing, feature engineering, model construction, training and validation, and performance evaluation. Based on the modeling characteristics of metallic service damage, several machine learning strategies are discussed. Pure data-driven models are used to establish nonlinear mappings between input features and damage or life indicators. Physics-informed machine learning incorporates empirical formulas, damage mechanisms, physical constraints, or prior knowledge into the modeling process, thereby improving physical consistency under small-sample or mechanism-constrained conditions. Transfer learning uses knowledge from related materials, similar service environments, or low-cost datasets to support prediction under limited target-domain data. Incremental learning allows models to update continuously with newly collected service data, which is relevant to online monitoring and life-cycle assessment. Ensemble learning combines multiple base models to improve prediction stability and reduce the dependence on a single model structure. This review further summarizes recent advances in machine learning research related to typical metallic damage modes, including corrosion rate prediction, fatigue life assessment, crack propagation analysis, creep life prediction, and multi-damage coupling modeling. For corrosion, machine learning models have been used to analyze the effects of alloy composition, environmental parameters, electrochemical signals, and image features on corrosion evolution. For fatigue, related studies focus on life prediction, fatigue strength evaluation, defect-sensitive modeling, time-series damage analysis, and crack identification. For creep, machine learning is applied to creep rupture life prediction, steady-state creep rate estimation, creep stage identification, and remaining life assessment under high-temperature conditions. For coupled damage, hybrid frameworks that integrate physical damage models with neural networks are discussed as a way to describe the interaction among corrosion, fatigue, creep, and other damage mechanisms. On the basis of existing studies, this review identifies several challenges in applying machine learning to metallic service damage assessment, including incomplete data records, insufficient model generalization, limited interpretability, weak physical consistency, and difficulty in online updating. It also offers insights into the development of multi-source data systems, physical mechanism constraints, coupled damage prediction, and intelligent operation and maintenance. These directions are expected to support the transition of machine learning from general performance prediction to service-damage-oriented life assessment and engineering maintenance decision-making.

     

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