Data-Efficient Indentation Size Effect Correction in Steels Using Machine Learning and Physics-Constrained Neural Network

The identification of constitutive neural network models from heterogeneous full-field deformation data provides a robust alternative to traditional calibration methods based on homogeneous stress-strain experiments, particularly given the high dimensionality of trainable parameters. Existing approaches must balance generality, robustness, and computational efficiency: Conventional finite element model updating is broadly applicable but computationally demanding; weak-form methods offer efficiency but are sensitive to noise and data scarcity; neural operator models are highly expressive but require extensive training datasets. This work presents FE-MAD (Finite Element-Based Material learning via Automatic Differentiation), an end-to-end differentiable framework that integrates a constitutive neural network model within a JAX-FEM nonlinear solver and identifies its parameters through gradient-based minimization of a measurement-mismatch loss. Newton tangent stiffness and loss gradients are computed automatically using forward- and reverse-mode automatic differentiation throughout the entire pipeline, thereby removing the need for analytic adjoints or offline surrogate models. FE-MAD is demonstrated for two architectures: a grey-box Constitutive Artificial Neural Network (CANN), a polyconvex, fully connected model with high flexibility, and a white-box CANN, an expert-system network with phenomenologically interpretable strain-energy terms. Focusing on incompressible isotropic hyperelasticity, FE-MAD is evaluated on three open experimental datasets: (1) full digital image correlation (DIC) of a perforated tensile specimen, (2) a reduced-data scenario with a one-dimensional stretch profile and global force-displacement curve, and (3) a heterogeneous matrix-inclusion system in which both phases constitutive laws are identified and generalized to twenty-two previously unseen samples.

Reliable correlations of Charpy impact test results between sub-sized and full-sized specimens are essential for structural integrity assessments, particularly in nuclear applications, where spatial constraints and limited material volume restrict specimen size. Although standards such as ASTM A370 and BS 7910 provide guidance on conversion methodologies, and numerous analytical correlation methods have been proposed in prior studies, these approaches generally have limited accuracy and their applicability is often constrained to specific materials, treatment conditions, and specimen geometries. In this study, a Machine Learning (ML)-based framework is proposed for correlating Charpy impact properties across specimen sizes. The proposed approach maps absorbed energy values across the full ductile-to-brittle transition region by applying a temperature shift combined with scaled residual projection, to align sub-sized test data with full-sized response. From the resulting temperature-energy profiles, the correlated values for upper shelf energy (USE) and ductile-to-brittle transition temperature (DBTT) are extracted by fitting data with a hyperbolic tangent model. The framework is validated using a dataset comprising 389 matched sub-sized and full-sized Charpy impact tests on SA533B steel. This ML-based approach demonstrates an improved correlation performance relative to conventional analytical methods, achieving R2 values of 0.942 for USE and 0.892 for DBTT. The trained ML models do not require access to full-sized Charpy data during inference, making this approach suitable for material surveillance programs, accelerated irradiation testing, and other applications involving small-size Charpy impact testing.

Stress localization in heterogeneous solids is governed by the bimaterial interface, where the displacement field remains $C^0$-continuous, while in-plane stresses jump due to the stiffness mismatch. Coordinate-based physics-informed neural networks (PINNs) represent this jump via a prescribed regularization width or a weighted interface penalty, making their accuracy sensitive to how phase-contrast changes are handled. This work presents a variational, label-free physics-informed graph neural network (PI-GNN) in which the heterogeneity is carried by the discretization rather than by the trial field. The solver operates on a conforming adaptive mesh graph, assigns constitutive behavior per element, and minimizes the discrete total potential energy as a single unweighted objective in which only first derivatives appear. The discrete energy on piecewise-linear elements coincides with the finite element (FE) Ritz functional. Dirichlet conditions are enforced by construction, with no penalty term, no interface weight, and no prescribed transition width. Using one fixed architecture, optimizer, and loss across small-strain elasticity and finite-strain Neo-Hookean hyperelasticity in two and three dimensions, the von Mises error remains below $3.58\%$ across a stiffness-contrast sweep spanning $(E_{\mathrm{inc}}/E_{\mathrm{mat}}\in[10^{-2},10^{2}])$, where a strong-form PINN degrades to $5.58\%$, and its displacement error reaches $7.66\%$ against $0.49\%$ for the PI-GNN. A trained network halves the ($σ_{xx}$) error of an energy-based PINN ($5.01\%$ versus $10.94\%$). Training cost exceeds a single FE solve by more than an order of magnitude, so the construction is a variationally consistent, penalty-free interface representation for parametric surrogates and inverse identification rather than a replacement for a one-off FE analysis.