Low-Magnification SEM May Suffice: Interpretable Deep Learning for Multi-Scale Fracture-Cause Classification in Zirconia-Toughened Alumina

Vision-language models (VLMs) have shown strong potential for scientific image understanding, but general-purpose models often lack the domain-specific visual knowledge required for reliable materials characterization. In this work, we fine-tuned an open-source VLM (Qwen3-VL-32B-Instruct) for fracture-surface image analysis using a curated dataset of 13,168 open-source, literature-mined fracture-surface images. Morphology annotations were generated by GPT-5.2-Reasoning (high) from both the images and relevant excerpts of their source papers, and the dataset was further enriched with targeted manual collection and rotation-based augmentation. The resulting specialist model outperforms flagship proprietary multimodal models on a benchmark of 100 manually annotated images. It achieves a precision of 0.92, compared to 0.35 for the base Qwen3-VL-32B-Instruct, 0.58 for GPT-5.5-Reasoning (high), and 0.78 for Gemini 3.1 Pro-Reasoning (high). Dataset ablations show that manual collection of rare-feature images and augmentation via image rotation are both beneficial to improve recognition of less common fracture morphology features. We further discuss integrated use of the fine-tuned model with proprietary models to combine fracture-specific visual accuracy with broader multimodal reasoning for autonomous fractography. Although focused on fracture-surface images, this work demonstrates how VLMs can be adapted through targeted collection and fine-tuning on novel feature images to recognize those features and support downstream decision-making in autonomous microscopy workflows.

Non-destructive testing of aerospace SiC/SiC composites via X-ray computed tomography (XCT) relies on expert visual assessment, with current workflows offering limited traceability for accept/reject decisions. Deep convolutional networks can automate defect detection, yet their black-box nature conflicts with the transparency that industrial inspection practice demands. To close this gap, we introduce p-ResNet-50, a convolutional framework extended with a prototype layer that couples high detection accuracy with case-based explanations. Six learned prototypes are explicitly aligned with expert-defined semantic categories-healthy matrix, matrix--air interfaces, pores, line-like defects, and mixed morphologies-so that every classification is traceable to a physically meaningful reference. Two novel regularisation terms, anchor-based and medoid-based, tether prototypes to expert-selected patches and prevent prototype collapse, addressing a known limitation of prototype networks. Latent-space analysis via UMAP delineates semantically coherent sub-domains and maps zones of uncertainty where misclassifications concentrate, giving inspectors an explicit picture of where the model is-and is not-reliable. The framework is validated on an XCT patch dataset of approximately 12,000 patches extracted from four defect-rich SiC/SiC laboratory specimens. Taking a black-box ResNet-50 as a baseline (ROC-AUC = 0.991), the prototype extension achieves comparable performance (accuracy 0.957 vs. 0.959; ROC-AUC 0.994 vs. 0.993) while trading a slight reduction in sensitivity for higher precision and specificity. Each decision is backed by representative evidence patches, and the model explicitly flags its uncertainty regions. Beyond defect mapping, the framework establishes a reusable methodology for embedding domain-expert knowledge into prototype networks, applicable to other XCT inspection scenarios requiring traceable, auditable decisions.

The full potential of artificial intelligence in tibial plateau fracture characterisation remains unrealised, constrained by a fundamental dependency on labelled datasets whose consistency cannot be guaranteed: conventional classification schemes such as Schatzker and AO/OTA suffer from inter-observer variability, causing supervised models to learn human disagreement rather than stable fracture morphology. We design, implement, and validate a label-agnostic framework that eliminates this constraint by learning fracture representations directly from imaging data without observer-assigned labels. A RadImageNet-pretrained ResNet-50 encoder is fine-tuned on 154 cleaned knee radiographs using the SimCLR contrastive objective, preceded by a data cleaning protocol and followed by UMAP dimensionality reduction and k-means clustering to discover four imaging-derived phenotypes. Phenotype validity is assessed through a blinded expert review protocol administered to two independent clinicians. The four phenotypes demonstrate robust stability (bootstrap ARI = 0.319 +/- 0.041), strong internal cohesion (silhouette = 0.511), and coherence ratings of 3-5/5 from both reviewers under blinded conditions; one phenotype was unanimously identified as exhibiting comminution -- a high-complexity feature isolated without any supervisory signal. Inter-partition comparison against Schatzker labels yields ARI = 0.013, confirming orthogonality to conventional classification boundaries. Notably, expert reviewers anchored to established classification vocabularies perceived imaging-derived groups as heterogeneous precisely where Schatzker alignment was lowest, suggesting that Schatzker-trained perception and label-agnostic embedding geometry measure orthogonal dimensions. These findings establish label-agnostic SSL phenotyping as a reproducible and clinically interpretable complement to conventional classification.