Fatigue Behavior Research Articles

Developing statistical tools to analyze historical stress-controlled fatigue data in additively manufactured austenitic stainless steel

The development of robust fatigue property data sets for additively manufactured 316L austenitic stainless steels is hindered by the small sample sizes, inconsistent reporting of material properties and processing conditions, and differences in testing procedures for current sources of testing data. By applying standardization and categorization protocols to account for these shortcomings, historical data sets were aggregated into a single large data set and analyzed in greater detail, providing new levels of insight into the stress-controlled fatigue behavior of additively manufactured materials. Using this single aggregated data set, scatter was quantified using an eigenvalue analysis, and a multi-variable statistical model for predicting the mean fatigue life was developed. Interactions between variables and the sensitivity to different loading conditions were then identified, with the scatter in the data being attributed to differences in testing and post-processing condition such as surface condition and heat treatment, and the model was used to identify the role that each variable plays in determining fatigue life. An analysis of the fatigue responses across the aggregated data set using clustering algorithms allowed two distinct trends to be identified and attributed to the differing roles of microstructure and porosity on the resulting fatigue lives across different equivalent stress amplitude ranges.

Fatigue behavior analysis and life evaluation method of building steel under the influence of multiple factors

The paper aims to analyze the stress–strain response of building steel under low-cycle multiaxial fatigue and to accurately evaluate the fatigue life of specimens by selecting the more important relevant factors that affect fatigue behavior. Based on this, low-cycle multiaxial fatigue experiments of Q355D notched specimens under different multiaxial loading are carried out. Firstly, the fatigue behavior of notched specimens under different loadings and the relationship between the biaxial strain amplitude ratio and fatigue life are analyzed. Secondly, Grey correlation analysis, Pearson correlation analysis, and Random Forest importance analysis are used to screen out the important factors affecting fatigue life. Finally, the grey MGM (1, N) model is used to predict the fatigue life of notched specimens, and the results show that the predicted life based on Random Forest importance analysis is in good agreement with the experimental life. In this paper, the multiaxial fatigue problem is decoupled into two sub-problems, i.e. screening out related factors and life prediction based on the related factors, which can be used as a reference for life prediction in structural design.

Fatigue behavior of pultruded fiberglass tubes under tension, compression and torsion

This work is devoted to an experimental investigation of fatigue behavior of pultruded fiberglass tubes under uniaxial tension, compression and torsion. Static tests were carried out; a presence of postcritical deformation stage during torsion is noted. Regularities of inhomogeneous strain fields evolution are analyzed using digital image correlation method. Fatigue curves are built for four cyclic loading modes: tension-tension, compression-compression, tension-compression and torsion. An analysis of specimens' fractures is carried out, typical damaging mechanisms are revealed. Residual dynamic stiffness data is obtained and studied using a previously proposed fitting model. Results demonstrate model's high descriptive capability and its flexibility to describe two-staged and three-staged stiffness degradation curves. An influence of loading mode on a shape of these curves is found out. Model parameters' dependence on maximum stress value during the loading cycle is studied using the Pearson's correlation coefficient. The necessity of multiaxial fatigue behavior investigation of pultruded fiberglass tubes is concluded.

Modelling of flexural fatigue behaviours of hybrid engineered cementitious composite link slabs using cycle-driven analysis

Link slabs are designed and expected to be serviced under high-cycle traffic loadings. Although their high-cycle fatigue performance is critical in their practical applications, very few experimental and numerical studies have been conducted to study high-cycle fatigue failure of link slabs due to the huge amount of time and resources needed for fatigue tests and the lack of efficient modelling method for high-cycle fatigue failure. Recently, as a newly developed material with superior mechanical properties, the hybrid fibre reinforced engineered cementitious composite (hybrid ECC) has been recommended for link slab application. In this study, a novel and efficient cycle-driven analysis (CDA) procedure was developed to model the structural behaviour of ECC link slabs made of the hybrid ECC under high-cycle fatigue loadings, which is the first attempt for CDA to be applied in high-cycle fatigue structural modelling of a hybrid ECC link slab with reinforcement bars. In the proposed CDA, fatigue damages of both hybrid ECC and reinforcement bars were taken into account. The accuracy and reliability of the new CDA procedure were validated by comparing the modelling predictions with the experimental results on two quarter-scaled hybrid ECC link slabs. It was found that the proposed CDA procedure could predict the overall fatigue behaviours including the deflection histories, crack patterns, fatigue life, fatigue failure mode and the residual static strength of the hybrid ECC link slabs after fatigue damage with good accuracy.

Progress in adhesive-bonded composite joints: A comprehensive review

Among the myriad joining techniques, the adhesive bonding technique is widely used to join complex large-scale composite structures because of its numerous advantages compared to traditional joining techniques. This article profusely analysed the various techniques for ameliorating the performance of composite joints, such as bonding methods (secondary bonding, co-bonding, co-curing, and multi-material bonding), surface modification techniques (plasma, laser surface treatment, surface grinding, etc.), additional reinforcement techniques (Z pin, wire mesh, nanofiller, etc), and different joint geometries (stepped joints, half-stepped joints, balanced joints, and scarf joints). Also, the effect of various adhesives and fabrication techniques on the static and dynamic performance of CFRP and GFRP-based joints was studied in detail. Moreover, this review addresses the finite element modelling and optimisation techniques on adhesively bonded joints. It has been observed that the bonding methods, surface modification to enhance the roughness of the adherend, addition of nanofillers, and variations in joint geometry greatly influence the shear strength, fracture toughness, fatigue, and vibration behaviour of FRP composite joints.

Investigation on high cycle fatigue performance of additively manufactured Alloys: Synergistic effects of surface finishing and Post-Heat treatment

The high-cycle fatigue (HCF) behavior of additively manufactured (AM) materials in structural applications remains insufficiently explored when contrasted with conventionally fabricated alloys. Addressing this research gap, we systematically investigate the potential to enhance HCF performance in AM alloys through a strategic interplay of surface finishing and post-heat treatment design. Concentrating on laser powder bed fusion, we evaluate surface roughness and post-heat treatment effects on HCF life across a300to1000 MPa stress range. Findings show that, at700to1000 MPa, surface finishing significantly extends HCF life by mitigating crack initiation. Paradoxically, at300to700 MPa, it shortens HCF life due to induced local residual stress on the sample surface. Additionally, post-aging finishing moderately enhances HCF life compared to pre-aging. This underscores the crucial role of sequence in surface finishing and heat treatment, emphasizing their collective impact on fatigue properties. Our study advances the understanding of post-processing factors influencing AM alloy fatigue properties, providing valuable insights for enhancing mechanical performance.

A Review of the Studies on the Effect of Different Additives on the Fatigue Behavior of Asphalt Mixtures

The fatigue phenomenon significantly weakens road pavement due to repeated reloading. To enhance fatigue resistance, numerous studies have explored various additives in asphalt mixtures. This review focuses on key variables influencing the effectiveness of additives, including fibers, polymers, nanomaterials, waste materials, and biomaterials, in improving the fatigue performance of asphalt mixtures. The study initially identifies different additives and fatigue testing methods used for asphalt mixtures. It evaluates the impact of factors such as modifier content and size, base asphalt binder type, mixing processes, dispersion behavior, and testing conditions on the fatigue behavior of modified asphalt mixtures. The cost-effectiveness and environmental impact of additive application have also been assessed. Additionally, research gaps and future prospects for modified asphalt mixes are outlined. Existing studies demonstrate the benefits of additives like basalt fiber, polyester fiber, styrene–butadiene–styrene (SBS), nanosilica, crumb rubber, and biooils in enhancing the fatigue life of pavement constructions. However, challenges exist in the application of modifiers due to limited practical implications and insufficient knowledge. Further research is needed on factors such as additives’ dispersity, compatibility, aging resistance, economic viability, and modifying mechanisms in morphological and micromechanical aspects to enhance the fatigue performance of the modified asphalt mixture.

Thermomechanical fatigue behavior and its life prediction of AlSi9Cu3.5 cast alloy

Thermomechanical fatigue behavior and its life prediction of AlSi9Cu3.5 cast alloy

Laser-inherent porosity defects in additively manufactured Ti–6Al–4V implant: Formation, distribution, and effect on fatigue performance

Porosity defects are inherently present in Ti–6Al–4V (Ti6-4) parts produced using additive manufacturing (AM) methods like laser powder-bed fusion (LPBF). This work aims to investigate different laser-inherent porosity defects at various LPBF parameter settings and assess their impact on the fatigue behaviour of Ti6-4 implants processed by LPBF. The presence of LPBF-inherent porosity defects with different shapes and sizes was established using microstructural examination and X-ray micro-CT analysis. These mostly comprise lack-of-fusion porosity (LoFP), gas-entrapped porosity (GeP), and pores-induced microcracks. Volumetric porosity defects were seen to range from 1.9 × 104 to 9.52 × 105 μm3. The L-1 specimen exhibited the lowest defect, while the L-6 specimen displayed the largest number of defects. While LoFP defects predominate in L-6, there was a notable presence of GeP defects in the specimens processed using the factory default condition (L-D). Upon examination of the majority of specimens, GeP and LoFP coalesced to form clusters, leading to the formation of pores-induced microcracks. This ultimately leads to a decrease in fatigue performance. By maintaining the power at the default setting and increasing the scan speed by 8% of the default value, a specimen (L-1) with minimal porosity defects and superior fatigue performance is achieved. L-6 exhibits defects with significant dimensions and irregular form. Consequently, it displays inferior fatigue characteristics.

General investigations on the heat treatment and thermal fatigue behavior of an experimental hot work tool steel tailored for laser powder bed fusion

An experimental hot work tool steel with a leaner chemistry compared to the standard AISI-H13 grade, aimed at enhanced processability, was gas atomized and processed using laser powder bed fusion (L-PBF) to >99.8 % relative density. The lower carbon content (∼0.25 wt% vs. ∼0.4 wt% in H13) resulted in a softer as-built (AB), and quenched martensite (∼485 HV1 vs. 625 HV1 in H13), higher martensite-start temperature (∼360 °C vs. 280–320 °C), and about ∼18 % reduction in dilatation, ascribed to the volume expansive martensitic transformation. Charpy V-notch impact toughness in AB condition (>30 J) was higher than those reported for AB H13. These features account for the improved L-PBF processability. The tempering response in comparison with a wrought H13, was characterized by a larger precipitation of thermally stable Mo- and V-rich secondary hardening alloy carbides at the expense of the easy-to-coarsen Cr-rich ones, attributed to the higher Mo and lower Cr content in experimental alloy. The combination of lower C- and V-contents in experimental alloy, reduced the driving force for the precipitation of coarse vanadium rich carbides during austenitization, as confirmed by electron diffraction spectroscopy (EDS) and synchrotron X ray diffraction. This led to a stronger fine secondary hardening alloy carbide precipitation during tempering, and enhanced temper resistance. As elaborated by isochronal tempering, as well as tempering curves, reduction of the elements Si, and Cr shifted the secondary hardness peak to higher tempering temperatures. Consequently, tempering, and thermomechanical softening resistance was significantly enhanced in the new steel with a maximum hardness of ∼550 HV1 in over-tempered condition (i.e., slightly above secondary hardness peak). Thermal fatigue (TF) tests revealed a denser and finer TF crack network with a larger oxidation in experimental steel. Thereby, the TF crack penetration depth scaling with the local plastic yielding of the matrix was evidently shorter in the new steel compared with wrought H13, thanks to significantly improved hot hardness, thermal conductivity, and enhanced thermomechanical softening resistance. Finally, a proof of concept is demonstrated by processing a relatively large injection molding die (150 mm × 110 mm × 30 mm) with promising tensile and impact toughness properties after direct double tempering to 51 HRC, and 45 HRC hardness levels.

Fatigue Performance Evaluation of Fiber-Reinforced Asphalt Mixtures with Four-Point Bending Beam and Uniaxial Fatigue Tests

This study aimed to evaluate the fatigue cracking potential of aramid fiber–reinforced asphalt mixtures. Three fiber-reinforced asphalt mixtures (FRAMs) were prepared employing a singular aggregate type (diabase stone), one binder type (PG76-22), and two distinct combinations of aramid fibers at varying dosages. Two types of fiber were used at different dosages by weight of mix: polyolefin/aramid (PFA) fibers at a dosage 0.05% and sasobit-coated aramid (SCA) fibers at dosages of 0.01% and 0.02%. Additionally, an unreinforced (control) mix was also produced for comparison purposes. Each of the mixtures was produced at a batch plant, adhering to the fiber manufacturer’s recommended mixing methods, while maintaining a constant binder content of 5.5% based on the total mix weight. Four-point beam (4PB) fatigue, uniaxial fatigue (UF), and Texas overlay tests (OT) were performed to characterize the fatigue and reflective cracking behavior of FRAM. The 4PB test results suggest that FRAM improved the fatigue life at lower strain levels (400 µε and 600 µε); however, at higher microstrain (800 µε) level, FRAM exhibited lower fatigue life than the control mix. Damage characteristic curves obtained from the UF tests showed better fatigue tolerance for reinforced mixtures, regardless of microstrain level. For cycles to failure under tensile loading, UF and OT test results indicated lower fatigue life of reinforced mixtures compared with the control mix. Therefore, under flexural loading the fiber-reinforced asphalt mixtures tend to improve the fatigue life. However, for direct tension load, reinforced mixtures tend to deteriorate the fatigue life when comparing cycles to failure at constant strain amplitude.

Static and fatigue performance of non-circular rivet joints: Comparison between numerical modelling and preliminary testing

Alternative non-circular rivet joint geometries are investigated. An optimum non-circular rivet geometry based on a continuous change in the radius of curvature is proposed to minimise the stress concentration factor on structural components joined by rivets, which is the first time to be proposed to the best author’s knowledge. By-pass and bearing load cases are considered for both numerical analysis and a preliminary experimental programme. For isotropic materials, linear elastic analyses (for the stress concentration factors) and fully elastoplastic analyses are carried out in the numerical simulations. The experimental programme includes static tests (for both by-pass and bearing load cases) and fatigue tests (by-pass loading) for isotropic materials, whereas only static tests (for both by-pass and bearing load cases) are considered for orthotropic composites. The correlation of experimental and numerical results indicates that the reduction of the stress concentration factor plays an important role in improving fatigue behaviour and has almost no influence under static loading. Hence, the life of structural riveted components may increase, improving the life cycle of the entire structure in service.

Effect of natural aging by multifunction cavitation on plane bending fatigue behaviour of heat-treatable Al-Si7Mg aluminum alloys and its fatigue strength estimation

The effect of natural aging by multifunction cavitation (MFC) on the fatigue behaviour of heat-treatable Al-Si7Mg aluminum alloys was examined. Surface observation and plane bending fatigue tests were conducted for the MFC-treated aluminum alloys at a stress ratio, R, of −1. The hardness of aluminum alloy without T6 treatment was significantly increased by MFC due to both the work hardening and natural aging. MFC treatment improved the fatigue lives and the fatigue strength at N = 107 cycles of aluminum alloys due to the generation of compressive residual stress and increasing the surface hardness; however, surface pits were large enough to easily nucleate an initial fatigue crack. In addition, the fatigue strength at N = 107 cycles of MFC-treated aluminum alloys can be estimated considering the residual stress, pit size and surface hardness.

Self-Heating and Fatigue Assessment of Laser Powder Bed Fusion NiTi Alloy with High Cycle Fatigue Mechanisms Identification

Rapid methods for assessing the fatigue properties of materials have been developed, among which the self-heating method stands out as particularly promising. This approach analyzes the thermal signal of the specimen when subjected to cyclic loading. In this research, the self-heating method was utilized for the first time with laser powder bed fusion (LPBF) of NiTi alloys, examining two specific loading conditions: loading ratios of 0.1 and 10. A thorough examination of the material self-heating behavior was conducted. For comparative purposes, conventional fatigue tests were also conducted, alongside interrupted fatigue tests designed to highlight the underlying mechanisms involved in high cycle fatigue and potentially self-heating behavior. The investigation revealed several key mechanisms at play, including intra-grain misorientation, the emergence and growth of persistent slip bands, and the formation of stress-induced martensite. These findings not only deepen our understanding of the fatigue behavior of LPBF NiTi alloys but also highlight the self-heating method potential as a tool for studying material fatigue.

Study on Corrosion Fatigue Behavior of 304L Austenite Stainless Steel in 325 °C High-Temperature Water Environment

The fatigue crack growth behavior of 304L austenitic stainless steel (SS) in a 325 °C high-temperature and high-pressure water environment were investigated by a corrosion fatigue test system, by electron back scatter diffraction (EBSD), and by a transmission electron microscope (TEM). The experimental results indicated that the crack growth rate (CGR) of 304L SS increases with increasing the stress intensity factor, stress level, and fatigue frequency (f). Compared to dissolved hydrogen (DH) in a high-temperature water environment, dissolved oxygen (DO) significantly enhances the CGR by about an order of magnitude higher. The crack tip of 304L SS after the corrosion fatigue test under higher stress levels is sharper, with more secondary cracks on the fracture surface, while the crack tip under lower stress levels is blunter with relatively fewer secondary cracks. The oxidation behavior at the crack tip was analyzed under different loading and water chemistry conditions, and a related effect on the crack tip and CGR was clarified.

Multi-scale measurement of constitutive viscoelastic properties of bituminous composites considering moisture and deicing conditions

The use of salt and chemical deicers can cause significant damage to road infrastructures. This study investigates the impact of different deicers on the viscoelastic properties of mastic and asphalt mixtures, with a focus on characterizing their behavior at varying temperatures and loading frequencies. The samples were subjected to conditioning in solutions of distilled water, salt, Calcium Magnesium Acetate (CMA), and Potassium Acetate (KAc) at 60 °C for 96 h, followed by frequency sweep and dynamic modulus tests at different temperatures and loading frequencies. The results indicate that moisture conditioning with distilled water softens asphalt mixtures and mastic at low loading frequencies, while brine softens the former at low temperatures. Salt's high interaction with mixture aggregates cannot be ignored. CMA's effect on the fatigue behavior of mastic samples is highly dependent on loading frequency, while KAc increases stiffness at intermediate and high temperatures. All the deicers reduce resistance to rutting damage, with CMA having the most negative effect. Both the 2S2P1D and the generalized Maxwell model can well (R2 ≥ 0.90, Se/Sy ≤ 0.35) predict the viscoelastic properties of dry asphalt mixture. However, in the presence of distilled water and the deicers, asphalt mixture viscoelastic properties cannot be predicted according to asphalt mastic characteristics by implementing the homothety method which indicates different effects of distilled water and the deicers on various scales of bituminous composites.

Fatigue and failure behaviour of friction welded steel joints under normal and shear stresses

Rotary friction welding is a fast and efficient joining process with the possibility to join materials that are not weldable by conventional GMAW-processes. If done properly, the welds have a static and fatigue strength higher than the base material. However, in literature, there exists only sparse information on the design and assessment of these joints in terms of fatigue. The fatigue strength of two material combinations, S355-S355 and S355-1.4301, is investigated based on two specimen conditions, (1) with flash and (2) with flash mechanically removed. In the majority of tests, failure occurred outside the weld zone, in the base material. The derived endurable nominal stresses are compared to the design S-N curve of conventionally welded specimens and show a more than 50% higher fatigue strength.

Exceptional fatigue-resistant austenitic stainless steel for cryogenic applications

Most alloys change from ductile to brittle at cryogenic temperatures, whereas high-entropy alloys show better strength, ductility, and toughness. However, they suffer from cost and mass-production challenges. We discerned the fatigue behaviour of a cost-effective austenitic stainless steel, SS316L, at an ultra-low temperature (ULT) of 15 K. For the cryogenic applications, our work demonstrates that compared to room-temperature (RT), ULT exhibits eight times higher fatigue life, despite even higher applied stress [ σmax=1.3×σysRT/ULT (280 MPaRT; 517 MPa15 K)]. At 15 K, the fatigue mechanisms involve stacking faults, a two-step martensitic phase transformation (γ→ϵ→α′) and α′-martensite twinning, utilizing the applied fatigue strain efficiently. The remarkable improvement in the mechanical strength and fatigue life at ULT is the key to revolutionizing sustainable advancements in space exploration and energy storage.

Fatigue behavior of adhesive joints under modes I and II fracture in carbon-epoxy composites, influence of exposure time in a saline environment

This work investigates the fatigue crack growth behavior of adhesive joints under pure modes I and II within epoxy matrix composites reinforced with unidirectional carbon fibers. Experimental tests are made using Double Cantilever Beam (DCB) and End-Notched Flexure (ENF) setups for modes I and II respectively, considering exposure periods of one week and twelve weeks in a salt spray chamber. Control specimens are also studied for comparison.Static tests were conducted to securely establish the levels of Energy Release Rate (ERR) that were subsequently used to obtain the fatigue initiation curves (G-N) and fatigue crack growth curves (G-da/dN). A probabilistic model based on a Weibull distribution is applied to analyze fatigue initiation data.The fatigue limit in mode I, for all aging periods, is around 25 % of the static strength, while in mode II, it is around 20 %. These results are very close at all aging levels (0, 1, and 12 weeks). From this, it is inferred that aging in a saline environment of the studied joints does not have a significant impact on the fatigue limit.In the crack growth zone, for mode I, the velocity is higher in the specimens aged in both periods than in the unaged specimens. The same cannot be said for mode II, where a clear trend cannot be appreciated.

Flexural fatigue behavior of ultra-high performance concrete under low temperatures

Ultra-high performance concrete (UHPC) shows superior mechanical performance, which leads to increasing applications in infrastructure constructions that are subjected to different loading (i.e., flexure, tension, compression, etc.) and environmental conditions (ambient, freeze, etc.). Among them, the flexural performance of UHPC under low temperatures (i.e., sub-zero temperature) is still little understood especially under fatigue loading. To investigate the flexural fatigue properties of UHPC under low temperatures, eleven UHPC prisms are subjected to cyclic bending at different stress levels from 0.40 to 0.80 (the ratio between applied maximum fatigue stress and static flexural strength) and temperatures of 20 °C, -10 °C, and -20 °C. Results indicate that the fracture interfaces for specimens under static and fatigue loading exhibit distinct differences. No fiber buckling appears for the monotonically-loaded specimens, while for specimens under fatigue loading, fibers buckled and fractured. Low temperature improves the mechanical properties of UHPC under monotonic loading due to enhanced matrix strength. Conversely, low temperature adversely affects the flexural fatigue performance of UHPC due to the cold brittleness nature of matrix and steel fibers, leading to the accumulation of matrix deterioration and the fracture of steel fiber. When the temperature drops from 20 °C to -10 °C and -20 °C, there is a 15.0 % and 12.7 % decline in the flexural fatigue strength of UHPC, respectively. In addition, low temperature accelerates the degradation of UHPC, resulting in a larger and faster accumulation of fatigue deformation, including tensile strain, mid-span deflection, and fatigue deformation modulus.