Fatigue Behavior Research Articles

A comparative study of self pierceing riveting and mechanical clinch of DP590-Al5754 high-strength steel and aluminum alloys

This paper presents a comparative study of two joining processes, self piercing riveting (SPR) and mechanical clinch, used to join DP590 high-strength steel and Al5754 aluminum alloy. A comparative study of microhardness, tensile shear properties, fatigue properties, and economics of joints from both processes was conducted. The findings indicate that the highest hardness levels are observed in the rivet leg region for SPR joints and in the neck region for mechanical clinch joints. The maximum failure load and energy absorption values of SPR joints were found to be 1.46 and 9.07 times higher, respectively, than those of mechanical clinch joints. The static tensile test results demonstrate that the strength and hardness of SPR joints in aluminum sheets subjected to cold work hardening are significantly lower than those of steel sheets. Therefore, the failure of SPR joints is primarily attributed to the deformation and fracture of the lower aluminum sheet. Mechanical clinch joints fail by neck fracture because the steel sheet neck becomes brittle by cold work hardening and the neck thickness is small. The fatigue behavior of SPR joints was observed to be superior to that of mechanical clinch joints. The findings of the scanning electron microscopy and energy spectrum analysis suggest that fretting wear between the upper and lower sheets results in fatigue fracture of the lower sheet in the joints. When joining the same material on a large scale, the selection of mechanical clinch over SPR can prove an effective method of reducing costs. Furthermore, the selection of a set of dies with an extended life can contribute to the reduction of joining costs.

Experimental investigation and computational modelling of 304LN stainless steel under constant and variable strain path multiaxial loading conditions

This study investigates the fatigue behavior of 304LN stainless steel under constant and variable strain path multiaxial loading conditions. Experimental methods and computational modelling were used to analyze the response of the material to different loading scenarios. Experimental investigations were conducted to gather empirical data, which were subsequently validated using a modified Ohno-Wang and Tanaka cyclic plasticity framework. Two models were used for the analysis: the MOT model and a modified model that incorporated a weighted function and fractional functions for hardening and softening. In contrast, the modified model offers significant improvements, accurately capturing primary hardening and secondary softening across all loading scenarios. Furthermore, the modified model effectively simulates transient behavior, including load alteration and recovery effects, due to the integration of load history memory regulating functions. Overall, this study emphasizes the importance of considering the complexities of cyclic loading and the sensitivity of the material behavior to the loading history.

Experimental study on the fatigue behavior of CFRP-strengthened cracked steel plates under eccentric axial tension

In this paper, an experimental investigation has been conducted to study the fatigue behavior of single edge-notch steel plates strengthened with CFRP (laminates/sheets). The plates have been subjected to eccentric fatigue under axial loading conditions. The experimental study includes fourteen specimens and has been tested under axial loading until failure. The constant parameters in the study are steel material grade, steel plate dimensions, and fatigue loading conditions. Meanwhile, the studied parameters are steel plate initial edge crack size, CFRP configurations (length, one or two-sided, and laminates or sheets), and adhesive material strength. The experimental results revealed that the fatigue life for specimens strengthened with CFRP sheets or CFRP laminates can be improved by a factor of 1.15 to 3.87 and 1.47 to 6.32, respectively, compared with the un-strengthened specimens. The results show that using CFRP can be considered an efficient way to repair the initial cracks in steel elements under eccentric axial fatigue loading.

Multiaxial fatigue life assessment of dental implants

As screwed joints, dental restorations may suffer mechanical failures such as screw loosening and implant or prosthetic screw failure due to fatigue. This work is focused on the failure of the implant and develops a numerical methodology to predict its fatigue life under cyclic loading conditions. This methodology is based on the combination of Critical Plane Methods and the Theory of Critical Distances to account for stress multiaxiality and notch effects. The obtained predictions were validated experimentally, which can be used to identify the main geometrical, assembly and operational factors affecting the fatigue behavior of dental implants. As a result, a powerful and efficient design tool for fatigue life prediction of dental implants is presented. This methodology complements a previously presented one focused on the fatigue life prediction of the prosthetic screw, thereby, offering now a complete design tool package regardless the critical component of the dental restoration, predicting accurately the fatigue response of the restoration, with no need for long-term fatigue test campaigns. This is a pioneering work since no other fatigue design methodology for dental implants with such a solid foundation and experimental validation has been published to date.

Flexural behavior of corroded RC beams repaired with high performance cementitious mortar under cyclic loading

AbstractThe understanding of the cyclic performance of reinforced concrete (RC) elements is of vital importance in relation to the extent of the service life of buildings and infrastructures. Steel rebar corrosion plays a major role in this regard because it significantly affects the overall structural integrity, especially under cyclic loads, leading to reduced stiffness and load‐bearing capacity of structural elements. Cyclic condition has the potential to accelerate the corrosion‐induced cracking and spalling, the effectiveness of the bond strength between rebar and concrete, and also the ductility and energy dissipation characteristics of the structure. The primary objective of this study is to investigate the effectiveness of a high‐performance thixotropic repairing cementitious mortar in improving the fatigue behavior of RC elements through a multiscale experimental approach. First, at the material scale of concrete specimens, two different concrete classes together with the repairing one‐component, pre‐blended, thixotropic cementitious mortar, were tested under incremental cyclic condition. Based on the results obtained from material scale, four reinforced concrete beams were exposed to different levels of accelerated corrosion by means of the impressed current technique and, subsequently, repaired by bonding a layer of the thixotropic high‐performance mortar onto the tension side. Finally, beams were tested under incremental cyclic four‐point bending test to investigate the fatigue behavior in terms of crack onset, propagation and energy dissipation. The resulting cyclic properties and cracking behavior of the structural elements were related to the level of corrosion achieved through the accelerated test and the effectiveness of the structural repair mortar was proven. In terms of code compliance, the repairing mortar was able to fulfill the requirements of frequent and quasi‐permanent combination of loads, remaining below all the threshold values provided by the Italian NTC2018 and Eurocode.

Low-cycle fatigue behaviour of concrete-filled double skin steel tubular (CFDST) members for wind turbine towers

Wind energy has the advantages of being clean and renewable. Wind turbine towers endure horizontal cyclic loads that could influence the performance of entire structure. To clarify the low-cycle fatigue behaviour of concrete-filled double skin steel tubular (CFDST) members, a total of 16 specimens were experimented. The hollow, slenderness, and axial compression ratios are specifically designed to clarify the effects on performance under constant amplitude loading and hysteretic loading conditions. The typical failure modes under both loading conditions and the relationship between loop strain, loop bearing capacity, loop energy dissipation, cycle number, and various degradation indices were analysed. Studies indicate that the failure mode under low-cycle fatigue loading is mainly local deformation, which includes transverse fracture occurring at the region between the steel tube and ribbed stiffener, the crushing concrete. Fatigue specimens with different amplitudes exhibit varying shapes of hysteresis responses. Higher amplitudes could enhance damage and significantly reduce fatigue life. Increasing the hollow and axial compression ratios boosts the energy dissipation capacity, and decreasing the slenderness ratio enhances the lateral resistance. A 2 % constant amplitude preload intensifies the degradation of bearing capacity and energy dissipation under subsequent constant amplitude loading.

Effect of the countersunk rivet head dimensions on fatigue behavior of riveted specimens of 2024-T3 alloy

PurposeThis study aims to investigate the effect of countersunk rivet head dimensions on the fatigue performance of the riveted specimens of 2024-T3 alloy.Design/methodology/approachThe relationship between rivet head dimensions and fatigue behavior was investigated by finite element method and fatigue test. The fatigue fracture of the specimens was analyzed by scanning electron microscopy.FindingsA change of the rivet head dimensions will cause a change in the stress concentration and residual normal stress, the stress concentration near the rivet hole causes the fatigue crack source to be located on the straight section of the countersunk rivet hole and the residual normal stress can effectively restrain the initiation and expansion of fatigue cracks. The fatigue cycle will cause the rivet holes to produce different degrees of surface wear.Originality/valueThe fatigue life of the specimens with the height of the rivet head of 2.28 mm and 2.00 mm are similar, but the specimens with the height of the rivet head of 1.72 mm were far higher than the other specimens.

Effect of loading sequence on the ultra-low-cycle fatigue performance of all-steel BRBs

Buckling-restrained braces (BRBs) are intended to protect the primary structure of buildings by absorbing most earthquake input energy through the plastic deformation of the steel cores. The ultra-low-cycle fatigue performance of BRBs is crucial for their seismic performance as energy dissipators. Despite the plenty of research on the ultra-low-cycle fatigue behavior of steel members, it remains susceptible if arbitrary loading paths have a major effect on the ultra-low-cycle fatigue life or cumulative plastic deformation (CPD) capacity of BRBs. This paper introduces an experimental campaign of nine supposedly identical BRB specimens subjected to three different loading protocols of similar average strain amplitudes. For each loading protocol, the test was repeated for three times to account for possible uncertainty. The results show that the effect of loading protocol is trivial given the similar average strain amplitudes throughout the loading. The Miner's assumption that the loading sequence has no effect on the fatigue life of BRBs is supported by the test results, however, the proper choice of the Coffin-Masson model's parameters is crucial. The skeleton ratio, which is derived from decomposing the hysteresis curve into a skeleton part and a Bauschinger part and has been used to account for the loading path effects, is shown to be insensitive to varied loading protocols by the test results.

Enhancing Fatigue Resistance of Polylactic Acid through Natural Reinforcement in Material Extrusion.

This research paper aims to enhance the fatigue resistance of polylactic acid (PLA) in Material Extrusion (ME) by incorporating natural reinforcement, focusing on rotational bending fatigue. The study investigates the fatigue behavior of PLA in ME, using various natural fibers such as cellulose, coffee, and flax as potential reinforcements. It explores the optimization of printing parameters to address challenges like warping and shrinkage, which can affect dimensional accuracy and fatigue performance, particularly under the rotational bending conditions analyzed. Cellulose emerges as the most promising natural fiber reinforcement for PLA in ME, exhibiting superior resistance to warping and shrinkage. It also demonstrates minimal geometrical deviations, enabling the production of components with tighter dimensional tolerances. Additionally, the study highlights the significant influence of natural fiber reinforcement on the dimensional deviations and rotational fatigue behavior of printed components. The fatigue resistance of PLA was significantly improved with natural fiber reinforcements. Specifically, PLA reinforced with cellulose showed an increase in fatigue life, achieving up to 13.7 MPa stress at 70,000 cycles compared to unreinforced PLA. PLA with coffee and flax fibers also demonstrated enhanced performance, with stress values reaching 13.6 MPa and 13.5 MPa, respectively, at similar cycle counts. These results suggest that natural fiber reinforcements can effectively improve the fatigue resistance and dimensional stability of PLA components produced by ME. This paper contributes to the advancement of additive manufacturing by introducing natural fiber reinforcement as a sustainable solution to enhance PLA performance under rotational bending fatigue conditions. It offers insights into the comparative effectiveness of natural fibers and synthetic counterparts, particularly emphasizing the superior performance of cellulose.

Rotating bending fatigue behavior of high-pressure diecast AlSi10MgMn alloy based on T5 heat treatment parameters

Abstract The study investigates fatigue failure, a common phenomenon in machine elements subjected to cyclic stresses. The analysis emphasizes that the actual stress experienced by materials often falls below their tensile and yield strengths due to repetitive variable stresses, leading to fatigue damage. Fatigue life is measured by the number of cycles endured before failure. This paper focuses on the aluminum alloy of AlSi10MgMn, extensively used in manufacturing due to its strength, low density, and corrosion resistance. Experimental procedures encompassed tensile testing, microstructural examination, SEM analysis, and fatigue testing. Tensile tests provided initial stress values for fatigue testing. Microstructure analyses verified that heat-treated samples exhibited precipitates. SEM analysis disclosed microstructural characteristics, while fracture surface examinations demonstrated higher fatigue resistance in heat-treated specimens. Hardness measurements were conducted, with heat-treated samples showing higher values. Theoretical calculations based on stress and cycle numbers were compared to experimental fatigue results. The derived equations aligned well with the tests. Ultimately, the study underlines the importance of heat treatment on material behavior and fatigue resistance, shedding light on alloy performance and durability enhancement.

Characterization of fatigue behavior of 3D printed pneumatic fluidic elastomer actuators

Soft robots have gained significant interest due to their high flexibility and adaptability to various working conditions. Recent advancements in engineering and innovative materials have enabled the design and production of sophisticated soft robotic systems with enhanced capabilities. This study aims to evaluate the fatigue behavior of bellow-type pneumatic soft actuators fabricated through fused filament fabrication (FFF) using thermoplastic polyurethane (TPU), compared to silicone rubber cast actuators. The actuators were equipped with resistive flex sensors to monitor bending motion, and fatigue tests were performed with cycles of inflation and deflation until failure. Results showed that 3D printed TPU actuators could withstand a significant number of cycles before failure, with an average of 6410 cycles at 3 bar pressure, compared to 3439 cycles at 1 bar pressure for the silicone actuators. The study identified a set of fabrication parameters that positively affect the durability of TPU actuators, providing valuable insights for replicating these results. Additionally, the study established a plausible range of utilization for 3D-printed FFF actuators in terms of the number of cycles they can endure, offering critical data for engineers and designers to make informed decisions about the design and application of these actuators in various practical scenarios. The findings demonstrate the potential of FFF for producing durable, long-lasting pneumatic soft actuators.

The interpretable descriptors for fatigue performance of wrought aluminum alloys

Aluminum alloys are extensively utilized in the transportation and aerospace industries due to their excellent processability and corrosion resistance. A key aspect affecting the application of aluminum alloys is fatigue failure, with fatigue strength constituting an essential indicator for assessing the failure mode. In this study, 859 data sets were collected to evaluate the effects of aluminum alloy composition and mechanical properties on fatigue strength. To comprehensively evaluate the features that exert a great influence on the fatigue strength of wrought aluminum alloys, atomic physical quantities of aluminum alloys were added to the original data set. To improve the computational efficiency and physical interpretability of the model, Spearman correlation analysis, optimal subset method, and other methods were used to perform feature selection on the atomic feature quantities and mechanical properties in the data set. Finally, a mathematical relationship between material descriptors and fatigue strength was established based on the alloy composition and the three most relevant features in the feature screening, which helps to better understand and predict the fatigue behavior of wrought aluminum alloys.

Effect of multi-pass overlapping friction stir processing on fatigue behavior of Al-Cu alloy

More than half of mechanical breakdowns stem from fatigue failure, often occurring suddenly and without warning. Friction stir processing (FSP) enhances the material's toughness and resilience to fatigue by refining its grain structure. This study investigates how multi-pass overlapping technique impacts the fatigue crack growth rate of FSPed Al-Cu alloy. Microstructural analysis revealed that the stir region exhibited uniformly dispersed and fragmented precipitates and finely recrystallized ultrafine grains. The hardness and strength were reduced, and ductility was enhanced after FSP due to high thermal cycling. Fatigue testing demonstrated a significant increase in fatigue life and reduced fatigue crack growth rate attributable to the combined effects of precipitation and grain refinement during cooling-assisted FSP. SEM examination of fatigue fracture surfaces revealed dimples indicative of ductile failure in the rapid crack propagation zone, while the steady-state propagation region displayed striation markings and secondary fractures.

Managing fatigue transdiagnostically: a qualitative study among people with chronic conditions on optimizing daily activity

Purpose To explore fatigue and physical activity behavior experiences and management, with an emphasis on activity pacing among adults with chronic conditions. Materials and Methods Semi-structured interviews were conducted with 15 adults with chronic conditions and the symptoms of chronic fatigue who had either received or not received fatigue management advice. Interviews were audio-recorded and transcribed verbatim, then analyzed using reflexive thematic analysis. Results Participants reported barriers to fatigue management such as overactivity, mental health issues, and workplace challenges. Additionally, they highlighted rest, restful activities, and supportive social environment as facilitators of effective fatigue management, along with the importance of nutrition and physical activity. In some cases, there were conflicting experiences with social environment and physical activity. Activity pacing was identified as a promising solution and participants recommended several strategies for future consideration. Conclusions Participants identified fatigue as a significant denominator in daily living and recognized the importance of activity pacing in fatigue management. Through reflective processes, they uncovered crucial factors for effective fatigue management, highlighting a multidimensional, interdisciplinary, and tailored approach to activity pacing as a promising solution. Further research should explore clinicians’ perspectives of a multidimensional fatigue management approach to further support optimal intervention design.

Low cycle fatigue behavior of AZ31 magnesium alloy joined by friction stir welding

AbstractThis study, aims to weld the 5.2 mm thick AZ31 magnesium alloy with conventional friction stir welding at the highest joining efficiency. As a result of the experiments, 88% joining efficiency in tensile strength has been obtained at 1250 rpm, 400 mm.min−1 welding parameter. As a result of micro–macrostructure photographic examinations of the samples joined with these parameters, it is seen that the joining is fully realized. Samples joined with these parameters have been used in fatigue tests. According to the strain‐controlled low cycle fatigue test results performed on welded and base metal samples, the base metal samples have exceeded the 50,000‐cycle limit without failure, with an elongation rate of 0.3%, and the welded samples with an elongation rate of 0.2%. Low cycle fatigue parameters of welded and base metal samples have been obtained according to the Coffin‐Manson‐Basquin equation.

Effect of welding residual stresses on the fatigue life assessment of welded connections

Welding residual stresses impose significant influences on the fatigue behavior and structural integrity of welded connections in various engineering applications. Understanding the effects of these residual stresses on fatigue life is crucial for ensuring the reliability and safety of welded structures. This paper proposes a damage-incorporated thermal–mechanical simulation method to examine the effect of welding residual stresses on the fatigue life prediction of welded plates and circular hollow section (CHS) X-joints. Compared to the experimental X-ray diffraction measurements and the fatigue tests, the predicted residual stresses and fatigue life demonstrate good agreement with experimental results for both high-cycle and low-cycle fatigue. The location of fatigue cracks resembles closely the estimation from a uniform fatigue damage indicator. The fatigue life prediction without incorporating the welding residual stresses does not affect significantly the life estimation for low-cycle fatigue but can cause substantial over-predictions for high-cycle fatigue.

Influence of Non-Metallic Inclusions on Very High-Cycle Fatigue Performance of High-Strength Steels and Interpretation via Crystal Plasticity Finite Element Method

The fatigue behaviors of high-strength bearing steel were investigated with rotating bending fatigue loading with a frequency of 52.5 Hz. It was revealed that the high-strength steel tended to initiate at interior non-metallic inclusions in a very high-cycle fatigue regime. During fractography observation, it was also seen that the inclusion acting as a failure-originating site was seldom smaller than 10 μm. Moreover, prior austenite grains could also act as the originating source of failure when inclusion was absent. The crystal plasticity finite element method (CPFEM) was adopted to simulate the residual stress distribution around non-metallic inclusions of different sizes under different loading amplitudes. The accumulated plastic strain around the inclusion suggested that the existence of inclusion may reduce material strength and lead to more fatigue damage. The value of accumulated plastic strain around different inclusion sizes also resembled the crack nucleation or propagation of the materials. The simulation results also indicated that inclusions smaller than 5 μm had little influence on fatigue lifetimes, while inclusions larger than 10 μm had a significant influence on fatigue lifetimes.

Effects of temperature and preload on fatigue behavior of train brake disc bolts

Effects of temperature and preload on fatigue behavior of train brake disc bolts

Effect of Fatigue and Precorrosion Fatigue on Fatigue Crack Propagation and Fracture Failure Behavior of 5B70 Aluminum Alloy

Aluminum alloys are ideal lightweight structural materials for spacecraft, but they are susceptible to local corrosion during service. Herein, a systematic investigation is carried out to determine the fatigue behavior of 5B70 aluminum alloy under salt spray precorrosion. The mechanism of salt spray corrosion, fatigue life, crack propagation, and failure fracture mechanism of 5B70 aluminum alloy are studied. Under the salt spray corrosion, 5B70 aluminum alloy mainly undergoes pitting corrosion via a galvanic corrosion mechanism. After precorrosion, the formation of macroscopic fatigue cracks is accelerated, which significantly reduces its fatigue life. Fracture occurs due to single crack initiation and propagation under fatigue conditions. The fatigue crack tip undergoes a mixture of intergranular and transgranular modes, but mainly transgranular mode. Multiple strain localization phenomena occur during precorrosion fatigue, and corrosion pits on the surface provide a tortuous crack propagation path; the fatigue crack tip is mainly transgranular mode.

Failure analysis of CFRP/Al single lap adhesive joint with enhancing porous metal foam insert

Cohesive failure is one of the main causes of adhesive bonding failure. The enhanced method and mechanism for adhesive signify a critical research issue for better adhesive joint design. This study proposes using a porous metal foam insert adhesive to enhance the carbon fiber reinforced polymer/aluminum single lap joint. In particular, stress distribution and failure locations of joints with and without insert were compared by simulation modeling. The insert of the Cu-foam, Fe-foam, and Ni-foam, compared to no insert, increased the shear strength of the bonded joint by 32.23 %, 36.66 %, and 66.82 %, respectively. Compared to no insert, the crack propagation of the joint with a metal foam insert was changed from the cross-section of the adhesive layer to the plane of the foam insert. The highest strength of the adhesive joint with the Ni-foam insert was further analyzed to determine fatigue behavior compared with pure adhesive joint under different stress levels. Compared to no insert, the fatigue life increased highly, and the crack path was prolonged.