Fatigue Life Behavior Research Articles

Fatigue behavior of polymethyl methacrylate/acrylonitrile butadiene styrene blends including blend composition, stress ratio, frequency, and holding pressure effects

In engineering applications, polymer materials are expected to exhibit superior fatigue life and balanced mechanical properties as essential performance criteria. The blending method is an important alternative in improving the performance criteria of ABS polymer in service. Thermogravimetric Analysis (TGA), Differential Scanning Calorimetry (DSC), Fourier Transform Infrared Spectroscopy (FTIR), and Dynamic Mechanical Analysis (DMA) methods were used for characterization. The effects of the PMMA fraction on the mechanical and fatigue behavior of PMMA/ABS blends were investigated by tensile and fatigue tests. Also, the influence of blend composition, stress amplitudes, stress ratio, holding pressure, and loading frequency on fatigue life is considered. The study improved yield strength, tensile strength, and elongation at break values of blends compared to ABS. In addition, 115 % and 75 % improvements were achieved in fatigue cycles at high and low-stress amplitudes with blends, respectively, for tension/tension loading. Similar improvements were obtained for fully reverse loading at 218 %. Thus, it was determined that the PMMA/ABS blend exhibited superior fatigue life in both tension/tension and fully reverse loading situations. Finally, it has been understood that PMMA/ABS blends can be designed to have mechanical properties and fatigue life behavior that can meet different requirements in conditions for engineering applications.

Method for the consideration of statistically distributed geometrical deviations in the design of cylindrical roller bearing arrangements

Rolling bearings are of great importance in all areas of mechanical engineering due to their precise and low-friction guidance of rotating components at low cost. The design of rolling bearing arrangements is usually based on approximately ideal geometries of bearings and adjacent parts on which the bearing seats are located. However, real components inevitably show statistically distributed deviations from their nominal shapes, which are limited by tolerances. Tight tolerances result in high manufacturing costs while on the other hand their expansion leads to an increase of occurring geometrical deviations which cause changes in the bearing-internal contact and load conditions and can thus impair the operating behavior of the bearing, e.g. with regard to fatigue life, frictional torque or vibration behavior. By taking these effects into account in the design stage, potential problems in operation can be identified early during development and countermeasures can be taken, e.g. by adjusting bearing and seat tolerances. This enables an improvement of overall product quality and a reduction of costs. This paper presents a method for the integration of component deviations in the computation of the fatigue life (Lnmr) and dynamic behavior of cylindrical roller bearing arrangements—both of which are crucial design criteria—based on a combination of statistical tolerance analysis and multi-body simulations. The method is applied to an exemplary use case for illustration.

Effect of electromagnetic force installation method on critically reinforced interference sizes and fatigue behavior of CFRP bolted joints

AbstractThe electromagnetic force dynamic installation (DI) method of interference fit fasteners has significant advantages in improving the quality of the assembly interface of composite structure. This study aims to investigate how improving assembly interface quality may help in achieving high‐precision interference‐fit joints in composites. Single‐lap joint specimens were prepared using electromagnetic installation technique, the fatigue life and failure behaviors of the joints under different bolt‐hole clearances were measured and analyzed experimentally. In addition, a three‐dimensional finite element model was developed to predict the radial pre‐compression stresses around the hole and the progressive failure behavior of various typical damage modes in carbon fiber‐reinforced polymer induced by the interference. The results show that the critical interference range for the DI‐composite bolted structure is 1.0%–1.2%. The fatigue life of the best interference (1.0%) and the worst interference (0%, neat fit) have a difference of 36 times in amplitude. The residual stress with uniform distribution and high amplitude reduces the stress concentration of the hole wall and improves the failure evolution of the loaded hole. The contribution of this study provides vital guidance for improving the fatigue performance of CFRP bolted structures using a novel DI method.Highlights I = 1.0% is the critical damage‐enhancing interference size for dynamically installation interference fit bolts with electromagnetic forces. The residual stress amplitude introduced by the interference does not increase uniformly as the interference size increases. Excessive interference significantly reduces the uniformity and magnitude of residual stresses. Under subsequent cyclic loading, the fifth layer near the inlet and outlet of the extruded lower laminate appears to be the critical ply of extrusion deformation, and severe damage is concentrated in the critical ply of deformation. The decrease of stress amplitude and the variation of mean stress are the mechanisms of fatigue life enhancement in interference fit joints under external cyclic loading.

Very high cycle fatigue of fiber‐reinforced polymer composites: Uniaxial ultrasonic fatigue

AbstractThis review explores uniaxial ultrasonic fatigue (USF) testing as a common and dependable method for quantifying the extended fatigue life of fiber‐reinforced polymer (FRP) composites. The objective is to explain the complexities governing the fatigue life behavior of FRPs, particularly in the realm of very high cycle fatigue (VHCF) where the number of loading cycles exceeds 107. To this end, this review encompasses the analysis of VHCF behavior, including the derivation and interpretation of stress–life (S–N) data, the evaluation of various fatigue damage mechanisms (i.e., controlling mechanisms of crack initiation and propagation) exhibited in FRP composites, and a thorough investigation of the frequency‐dependent effects on fatigue responses. Furthermore, this review tries to analyze the microscopic intricacies intrinsic to the VHCF failure of FRP composites, encompassing aspects such as fiber‐matrix de‐bonding, matrix cracking, and delamination, unveiling their modes and effects in a detailed manner. This review also underscores the pivotal integration of simulations, machine learning, and modeling techniques, emphasizing their crucial role in explaining both macroscopic and microscopic interactions governing the VHCF of FRPs.

A physics‐informed neural network framework based on fatigue indicator parameters for very high cycle fatigue life prediction of an additively manufactured titanium alloy

AbstractThe exploitation of fatigue life prediction methods based on fatigue indicator parameters revealed the influence of the defect size, position, and morphology on the fatigue life and fatigue behavior of additively manufactured metals. Meanwhile, Data‐driven life prediction methods are time‐efficient but inexplainable. Current machine learning‐based fatigue life prediction methods call for not only the accuracy but also the interpretability and stability of prediction results. Thus, the fusion of physical methods and machine learning methods has been a prevailing research topic in fatigue life prediction. In this study, a novel physics‐informed neural network framework is proposed by integrating a fatigue indicator parameter based on defects into the physical constraints term of a loss function. This method outperforms conventional machine learning methods in high‐cycle and very high‐cycle regimes, exhibiting superior prediction performance and generalization ability. Furthermore, the prediction results can be explained from a physical standpoint, correlating with the applicability range of the introduced physical equation describing defect positions.

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

The proposed review demonstrates the effect of the surface modification process, specifically, deep rolling, on the material surface/near-surface properties of commercial steels. The present research examines the various process parameters involved in deep rolling and their effects on the material properties of AISI 1040 steel. Key parameters such as the rolling force, feed rate, number of passes, and roller geometry are analyzed in detail, considering their influence on residual stress distribution, surface hardness, and microstructural alterations. Additionally, the impact of deep rolling on the fatigue life, wear resistance, and corrosion behavior of AISI 1040 steel is discussed. Engineering components manufactured by AISI 1040 steel can perform better and last longer when deep rolling treatments are optimized with an understanding of how process variables and material responses interact. This review provides critical insights for researchers and practitioners interested in harnessing deep rolling techniques to enhance the mechanical strength and durability of steel components across diverse industrial settings. In summary, the valuable insights provided by this review pave the way for continued advancements in deep rolling techniques, ultimately contributing to the development of more durable, reliable, and high-performance steel components in diverse industrial applications. The establishment of generalized standardizations for the deep rolling process proves unfeasible because of the multitude of controlling parameters and their intricate interactions. Thus, specific optimization studies tailored to the material of interest are imperative for process standardization. The published literature on the characterization of surface and subsurface properties of deep-rolled AISI 1040 steel, as well as process parameter optimization, remains limited. Additionally, numerical, analytical, and statistical studies and the role of ANN are limited compared with experimental work on the deep rolling process.

Comparison of fatigue life behavior between 4-point and uniaxial loading for L-PBF Ti–6Al–4V after HIP treatments

The present study investigated the effects of Hot Isostatic Pressing (HIP) on the fatigue performance of Laser Powder Bed Fusion (L-PBF) Ti–6Al–4V alloy under both 4-point bending and uniaxial testing. Three HIP-cycles were examined: standard, low temperature/high pressure (LTHP), and super beta. Moreover, an annealed heat treatment group was incorporated to compare against the HIP groups. The material microstructure was analyzed and compared across the heat treatments during the study, which showed the presence of α′ martensites, α+β Widmanstätten, and coarse equiaxed grains. Similarly, tensile and hardness testing were implemented to study the mechanical properties, where due to the effects of the HIP treatments, higher ductility but lower hardness values were recorded. Furthermore, fracture morphologies and stress-life (cycles-to-failure) (S–N) curves of the Ti–6Al–4V specimens concerning the fatigue behavior were analyzed. The HIP treatment groups behaved similarly during 4-point bending and uniaxial testing, with the LTHP obtaining a superior fatigue life behavior, followed by the standard and super beta HIP groups. In addition, the efficacy of HIP to reduce pores showed better results in the 4-point bending specimens, leading to few defects as fatigue initiators in contrast to the uniaxial specimens. Fractography results suggested that defects and microstructural features acting as fatigue crack initiators (FCI) govern the fracture behavior of uniaxial specimens. In contrast, only the presence of microstructural features controls the 4-point bending failure behavior.

Energy-Based Unified Models for Predicting the Fatigue Life Behaviors of Austenitic Steels and Welded Joints in Ultra-Supercritical Power Plants.

The development of a cost-effective and accurate model for predicting the fatigue life of materials is essential for designing thermal power plants and assessing their structural reliability under operational conditions. This paper reports a novel energy-based approach for developing unified models that predict the fatigue life of boiler tube materials in ultra-supercritical (USC) power plants. The proposed method combines the Masing behavior with a cyclic stress-strain relationship and existing stress-based or strain-based fatigue life prediction models. Notably, the developed models conform to the structure of the modified Morrow model, which incorporates material toughness (a temperature compensation parameter) into the Morrow model to account for the effects of temperature. A significant advantage of this approach is that it eliminates the need for tensile tests, which are otherwise essential for assessing material toughness in the modified Morrow model. Instead, all material constants in our models are derived solely from fatigue test results. We validate our models using fatigue data from three promising USC boiler tube materials-Super304H, TP310HCbN, and TP347H-and their welded joints at operating temperatures of 500, 600, and 700 °C. The results demonstrate that approximately 91% of the fatigue data for all six materials fall within a 2.5× scatter band of the model's predictions, indicating a high level of accuracy and broad applicability across various USC boiler tube materials and their welded joints, which is equivalent to the performance of the modified Morrow model.

Low cycle fatigue of EUROFER97 investigated for test blanket modules of ITER: An interlaboratory study

Several reduced-activation ferritic-martensitic (RAFM) steel grades have been proposed for structural applications in fusion reactors since the 1990s by several countries. The European reference RAFM steel EUROFER97 has been produced in four batches since 1998. It is intended for fabrication of Test Blanket Modules (TBM) for ITER as well as the blanket first wall and divertor cassettes of DEMO.RCC-MRx is the design code developed for high-temperature, research and fusion reactors by AFCEN. Its latest edition contains a provisional section dedicated to EUROFER97, aggregating properties of the first two batches, whereas a full qualification and final inclusion of a material requires three batches minimum. The completion of the code is required for the design assessment of TBM units in the frame of the nuclear licensing process.The EUROfusion project coordinates efforts to broaden the knowledge of EUROFER97 properties, which will be used for closing the database gaps in RCC-MRx. Low cycle fatigue (LCF) tests are a significant part of the EUROfusion test programme, since the material fatigue properties are indispensable for the component assessment owing to the cyclic nature of a tokamak operation.In this work we report the results of interlaboratory LCF tests on EUROFER97 batch 3 performed in a temperature range relevant for its application in ITER (RT–550 °C), wide selection of total strain ranges (0.3–1.5 %) and two values of strain ratio Rε (0 and –1). Along with the estimated fatigue life and cyclic behaviour, a fractographic analysis done with scanning electron microscopy (SEM) is presented.

Effect of surface modification on the high temperature low cycle fatigue performance of LPBF 316L austenitic steel

In this study, high temperature low cycle fatigue (LCF) tests at 550 °C were conducted on LPBF (Laser powder bed fusion) 316L with three different surface states, including the As-built surface (AB), fill contour (FC) manufacturing surface, and the surface combining FC and electropolishing (FC + EP). The effect of surface treatment on the high temperature LCF performance of LPBF 316L was investigated. Experimental results showed that the FC + EP surface treatment had the most significant effect on enhancing life. The difference in enhancing the fatigue life behavior was mainly attributed to the various crack initiation mechanisms with different surface states. The cracks on the surfaces of AB and FC mostly originate from the powder adhesion areas and the boundaries of the melt pool, while FC + EP surface treatment weaken the damage induced by powder adhesion. Furthermore, a parameter representing the fatigue crack propagation driving force that considers the surface condition has been defined, and a proposed life prediction model can provide guidance for surface modification and post-treatment of additive manufacturing materials as well as other metal materials.

XFEM based study on fatigue performance of rib-to-diaphragm welded joints considering initial defects

Orthotropic steel bridge decks (OSBDs) have been widely used in the field of bridges. However, their service life is significantly limited by fatigue issues. This study presents an analysis of the fatigue performance at the structural details of the rib-to-diaphragm joint, taking into account the impact of initial defects. A numerical segment model employing shell-solid coupling is established to determine the influence surface range and the most unfavorable working condition of the fatigue details, using fatigue standard vehicle loading. The accuracy of the local full-scale model is validated. A local model test of the rib-to-deck welded joint is carried out to deduce the parameter selection for the numerical simulation, based on the test results. Additionally, the crack propagation process in rib-to-diaphragm joints is simulated using XFEM. The simulation results of crack propagation demonstrate good agreement with the actual bridge crack path and shape. The crack propagation model can effectively evaluate the fatigue life, crack development stage, and shape of fatigue details. The study determines the effects of crack depth, crack length, and crack angle on fatigue performance. This study provides a basis for studying the residual fatigue life and crack propagation behavior of rib-to-diaphragm welded joints with initial defects. It is of great significance for understanding the crack propagation mechanism, formulating repair measures, and determining repair time.

Low cycle fatigue behavior and life prediction of a directionally solidified alloy

Low cycle fatigue behavior and life prediction of a directionally solidified alloy

Effect of surface coating on fatigue life and fatigue crack growth behavior of AISI D2 tool steel

To study the effect of the specimen surface coating on the fatigue life and fatigue crack growth behavior, rotating bending fatigue tests were performed with a specimen coated with a TiCN thin film on AISI D2 tool steel (JIS SKD11) and a bare specimen without coating. Fatigue cracks developed inside the specimen because compressive residual stress was present on the surface of the coated and bare materials. The fatigue crack growth behavior of the internal cracks was investigated with the two-stage double-stress experimental method proposed by the authors. The fatigue life estimated from the fatigue crack growth (FCG) behavior of the internal cracks and the experimental results agreed. Furthermore, a method was proposed that can easily evaluate the effect of residual stress on fatigue life and FCG behavior. The evaluation and experimental results are in good agreement. In addition, the effects of atmospheric and vacuum conditions on FCG behavior are discussed.

Fiber fracture behavior of high-pressure resin transfer molded (HP-RTM) carbon/epoxy multidirectional laminates under compression-compression fatigue loading

The influence of different stress levels on the fatigue life and fracture behavior of laminated composites have been evaluated under compression-compression (C–C) loading conditions. Carbon/epoxy multidirectional (MD) laminate specimen was designed with eight layers [0°, ± 45°, 0°]s of unidirectional plies. The preforms were molded by a high-pressure resin transfer molding (HP-RTM) process. As part of the study, a static compression test was performed. The C–C fatigue loads were applied at −260 MPa, −280 MPa, −300 MPa, and −320 MP compression stress until failure or two million cycle loadings. The fatigue limit has been obtained at −265 MPa stress by stress-cycle number (S-N) curve analysis, which is 51.4 % of static compression strength. The damage behavior was identified after C–C fatigue tests. By using optical and scanning electron microscopy, fiber fracture, matrix cracking, and fiber/matrix interface debonding were observed. Under the C–C fatigue loading conditions, fiber fracture modes were characterized by rough cross-sections, shear, and line-shaped edges.

Effects of temperature and strain amplitude on low-cycle fatigue behavior of 12Cr13 martensitic stainless steel

12Cr13 martensitic stainless steel has been selected as the structural material for steam turbine blade which is frequently subjected to low-cycle fatigue (LCF) damage. The study involved conducting low-cycle fatigue (LCF) tests under strain control at various temperatures (25 °C, 250 °C, 350 °C, 450 °C) and strain amplitudes (±0.3 %, ±0.4 %, ±0.5 %, ±0.6 %). The cyclic deformation behavior, primarily indicating cyclic stress response and the Massing effect is thoroughly analyzed based on the characterization of dislocation microstructure and electron backscatter diffraction maps. The mechanism of crack initiation and the propagation behavior are discussed based on the SEM observations of microcracks on the specimen surface and the fracture surface morphology. The influence of temperature and strain amplitude on fatigue life behavior is determined, and the underlying mechanisms are revealed. Moreover, the life prediction is performed by using the classical Basquin-Coffin-Manson model at ambient temperature.

Fatigue Life and Crack Growth Behavior of Ti-6Al-4V Fabricated via Laser Directed Energy Deposition

Fatigue Life and Crack Growth Behavior of Ti-6Al-4V Fabricated via Laser Directed Energy Deposition

Analyzing the macroscopic/mesoscopic mechanical properties and fatigue damage of graphene oxide/microcapsule self-healing concrete

Concrete materials used in transmission projects in Northwest China require specific properties, such as crack resistance, fatigue resistance, and low impedance. To meet these requirements, microcapsules with repair properties were synthesized using a physical method. Graphene oxide was employed as a conductive medium and reinforcing material to prepare standard concrete composite parts. Furthermore, the stress state and cracking behavior of the microcapsules in concrete were simulated through the Python-based secondary development of ABAQUS. An orthogonal test design was conducted to determine the optimal graphene oxide, microcapsule, and water–cement ratios. Based on the orthogonal test results, fatigue testing was conducted to assess the fatigue strength, fatigue life, and crack development behavior of the concrete under combined dynamic and static loading. The results show that the thickness of the microcapsule wall material directly influences the fracture extension and practicability of the concrete. Including a certain amount of graphene oxide can enhance the strength of the concrete, reduce its resistivity, and compensate for the microcapsule-induced early strength loss. The optimal graphene oxide/microencapsulated concrete ratios were determined as 3 % microcapsule admixture, 0.1 % graphene oxide admixture, and 0.45 water–cement ratio. Notably, at low stress levels, graphene oxide and microcapsules act synergistically to enhance concrete fatigue resistance. Graphene oxide/microencapsulated concrete exhibits higher residual fatigue strength than ordinary concrete; however, the difference in their fatigue resistance diminishes as the number of cycles increases.

High-Cycle Fatigue Life Behaviour of Fabricated Glass Fibre-Reinforced Polymer

This study focuses on the fatigue behaviour analysis of glass fibre-reinforced polymer (GFRP) composite specimens under high-cycle fatigue loading conditions. Therefore, property validation is recommended in the material development process upon further investigation of the fabricated GRFP. This study aims to evaluate the behaviour of the fabricated GFRP fatigue specimen when subjected to high-cycle fatigue loads and compare it to existing studies. A GFRP fatigue test sample was fabricated using the hand layup process into a flat rectangular panel, which was then cut into a small dimension of 28×2×0.2 cm fatigue specimen. Fatigue tests were performed on five flat specimens at different constant amplitude loads or stress levels between 40% and 80% of ultimate tensile strength to obtain the stress–life curve for the fabricated GFRP. Results showed that the high-stress levels of 80% contributed to the most reduced fatigue life cycle of GFRP. This result is consistent with previous studies and lies within the published life cycle range, validating the fabricated GRFP. A new parameter called the failure modulus, or Mf, may be used to quantify a particular set of fatigue tests.

Improved fatigue life of SLM-produced TC4 alloy treated by a pulsed magnetic field

Microstructural defects have been considered to be detrimental to fatigue life of SLM-produced TC4. To improve the fatigue property of the alloy, pulsed magnetic field (PMT) treatment, an efficient post-processing technique, was utilized in this work. The evolution concerning fatigue life, microstructure, stress state, and fatigue fracture behavior influenced by PMT was investigated. After the treatment, the average fatigue life under a certain load is increased by 471.13%, and the reliability of the life of the specimen is improved. The mechanism that PMT action on the microstructure lies in dislocation motion. It can be found dislocation density decreased evidently with more uniform distribution. Furthermore, with the influence of dislocation, superficial and internal residual stress (RS) of the material, in terms of magnitude, decreased by more than 60% and 10%, respectively. And superficial RS changed from a tensile state to a compressive state. Besides, the treated specimen exhibited better fracture behavior by comparatively analyzing microstructure alongside fatigue initiation. According to this comparison related to the primary slip system and dislocation, improvement of PMT on fatigue performance of SLM-ed TC4 can be validated.

Understanding the effect of nano‐zirconia on the compressive fatigue performance of cementitious composites

AbstractThe fatigue performance of cementitious composites that affects the service life of structures is particularly sensitive to the initial defects in cementitious matrix and interfacial transition zone. Nano‐ZrO2 (NZ), characterized by high strength and toughness as well as good dispersibility, can improve the compactness of cementitious composites. This paper investigated the modifying effect and mechanisms of NZ on the compressive fatigue performance of cementitious composites, including fatigue life, strength, and deformation behaviors. The experimental results show that adding NZ extends the fatigue life of cementitious composites by an order of magnitude and increases the fatigue failure strain by 11.9%. The microstructural analysis verifies that NZ can deflect the fatigue micro‐cracks, fill the micro‐pores and reduce the growth space of CH crystal size. The modified microstructures potentially lead to fatigue of cementitious composites starting from generating more nano‐cracks in both cementitious matrix and interfacial transition zone, thereby improving the fatigue performance of the composites.