Fatigue life prediction of aluminum 6061 alloy through experimental and numerical analysis under various stress ratios in axial tension-tension loading condition

Abstract

Aluminum alloy 6061 is a versatile material widely used in aerospace, automotive, marine, and structural applications due to its mechanical strength, weldability, and corrosion resistance. Understanding and addressing fatigue is crucial for ensuring the reliable and safe performance of components made from this alloy. This study focused on predicting the fatigue life of aluminum 6061 at room temperature under axial loading conditions and evaluating the fatigue life at various stress ratios. The experimental S-N curve, derived from tension-tension fatigue loading tests, was instrumental in characterizing the material's fatigue behaviour under constant amplitude loading condition. The data obtained from these tests were then imported into ANSYS software, a widely recognized tool for finite element analysis and simulation. ANSYS was used to conduct a detailed numerical analysis to predict the fatigue life of aluminum 6061 at different stress ratios. The results from the experimental and numerical analyses exhibited good agreement, validating the accuracy of ANSYS software in predicting fatigue life at different stress ratios. This study demonstrated the effectiveness of employing a combined experimental and numerical approach for understanding fatigue behaviour in materials, particularly in terms of its applicability to different loading scenarios. The findings from this research provide valuable insights into the fatigue life of aluminum 6061 under diverse stress ratios, with the goal of enhancing material design and engineering processes. By leveraging the capabilities of ANSYS software in conjunction with experimental data, the study established a reliable methodology for predicting fatigue life, which is crucial for optimizing the performance and longevity of components subjected to cyclic loading in various industries.