Crystal materials are prone to cracking during growth, which is a key problem leading to slow growth and difficulty in forming large-size crystals. In this study, based on the commercial finite element software COMSOL Multiphysics, the transient finite element simulation of the multi-physical field, including fluid heat transfer—phase transition—solid equilibrium—damage coupling behaviors, is performed. The phase-transition material properties and maximum tensile strain damage variables are customized. Using the re-meshing technique, the crystal growth and damage are captured. The results show the following: The convection channel at the bottom of the Bridgman furnace greatly influences the temperature field inside the furnace, and the temperature gradient field significantly influences the solidification and cracking behaviors during crystal growth. The crystal solidifies faster when it enters the higher-temperature gradient region and is prone to cracking. The temperature field inside the furnace needs to be properly adjusted so that the crystal temperature decreases relatively uniformly and slowly during the growth process to avoid crack formation. In addition, the crystal growth orientation also significantly affects the nucleation and growth direction of cracks. Crystals grown along the a-axis tend to form long cracks starting from the bottom and growing vertically, while crystals grown along the c-axis induce the laminar cracks from the bottom in a horizontal direction. The numerical simulation framework of the damage during crystal growth, which can accurately simulate the process of crystal growth and crack evolution and can be used to optimize the temperature field and crystal growth orientation in the Bridgman furnace cavity, is a reliable method to solve the crystal cracking problem.

Orientations, roughnesses, and cavities of crystals are typical factors influencing the servicing reliability of metals in corrosive environments. A phase-field scheme for modeling stress-corrosion coupled damage (SCCD) is developed. The effects of the crystal factors on SCCD are numerically simulated using the incremental-iterative scheme of the user-defined finite elements. The impacts of orientations, roughnesses, and cavities on the corrosion rate of magnesium (Mg) in corrosive environments are discussed quantitatively. It is found that crystal textures and surface roughnesses can significantly influence the diffusion-controlled corrosion rate. Strong basal texture and a smooth surface of the crystal can significantly enhance the corrosion resistance of Mg. The cavity, as a typical crystal defect, is capable of inducing the damage path and modulating the corrosion rate. The design of crystal-scale features, such as orientations, roughnesses, and cavities, is promising for the enhancement of the resistance to SCCD.