Genetic algorithms for high-precision reconstructions of three-dimensional topographies using stereo fractographs

A software is developed which enables reconstruction of the three-dimensional (3D) shape of fracture surfaces without human assistance. It is based upon computer image processing and pattern recognition techniques by using a stereo-pair of scanning electron micrographs. The processing consists of two subprocesses: searching the matching points between two images; and computation of heights using the relative shift of the matching points. By using the previously developed system, some mismatches were inevitable in the search process, in particular, for low-contrast SEM images, e.g. striations, intergranular facets, etc. In order to improve the accuracy of the search, a genetic algorithm (GA) was implemented into the developed system. By using the GA method, the 3D shapes of a wide variety of fracture surfaces including cleavage failures, intergranular cracking, dimples and fatigue striations, were successfully reconstructed with sufficient accuracy. The searching processes by the GA method and the previously developed two-step algorithm of coarse and close searching were compared. These proved that the GA method has both the advantage of accuracy in the searching process and a short run-time. A detailed 3D shape, of more than a 120 × 120 reconstructed point-sized shape, was thus obtained with sufficient accuracy and with a relatively short run-time.