High Cycle Fatigue Behavior Research Articles

High-Cycle Fatigue Behaviour and Structural Robustness of Glass Fibre-Reinforced Polymer Tiled Web-Core Sandwich Panel Unit Cells in Load-Bearing Structures

This paper explores the fatigue behaviour and robustness of tiled web-core sandwich panels used in glass fibre-reinforced polymer bridges, which are increasingly favoured for their lightweight and corrosion-resistant properties. Fatigue tests are conducted on unit cell specimens with manually induced crack initiation, simulating accidental damage scenarios in glass fibre-reinforced polymer bridge components. The objective is to assess the integrity of individual unit cells when subjected to a localized force at the top flange after damage initiation. The fatigue tests reveal three phases in the behaviour of a tiled unit cell. Initially, there is a substantial rapid stiffness degradation with crazing crack appearance within the cross-section. Subsequently, a plateau phase occurs, with limited stiffness degradation and stable crazing cracks, the duration of which depends on the applied fatigue load. Lastly, rapid stiffness degradation with substantial crack growth leads to ultimate failure within roughly a thousand cycles. Further analysis using digital image correlation reveals strain concentrations at the location of crazing cracks and crack propagation occurring interlaminarly but not through the plies of the top and bottom flanges, ensuring a robust design. This research enhances the understanding of the tiled sandwich panels, offering prospects for resilient load-bearing structures in glass fibre-reinforced polymer bridges and structural engineering applications.

High cycle and very high cycle fatigue behavior of additively manufactured Inconel 718: Effects of stress-relieving, surface texture, part orientation, and test frequency

High cycle and very high cycle fatigue behavior of additively manufactured Inconel 718: Effects of stress-relieving, surface texture, part orientation, and test frequency

Influence of the Loading Frequency on Very High Cycle Fatigue Behavior of Structural Steels

ABSTRACTIn ultrasonic fatigue tests, the VHCF properties can be determined in a reasonable time. Nevertheless, the high frequency can affect the fatigue behavior for some materials. This study investigated the fatigue capability of 34CrNiMo6 and 42CrMo4 steels, both of which find widespread applications in several mechanical components. These steels were carried out for conventional and ultrasonic fatigue tests under fully reversed testing conditions. A microplasticity strain amplitude was calculated, indicating an order of magnitude decreases around 10–100, when compared with the experimental results from low‐frequency tests. Cyclic strain rates were estimated for each steel and correlated with the number of cycles to failure. A conversion constant was obtained by fitting a curve to convert the high frequency results into theoretical results at low frequency. The experimental and predicted results were evaluated. The results proved the relevance of the strain rate in frequency effect. The converted results showed strong agreement with the experimental results in low‐frequency tests for the steels being studied.

Experimental study on high-cycle fatigue performance of laser cladding additively manufactured 316L stainless steel

Laser cladding (LC) technology has garnered significant attention for its application in the repair of corrosion damage in steel structures. However, research on the high-cycle fatigue performance of LC materials remains limited. This study employed 316L stainless steel powder to produce LC specimens and conducted uniaxial tensiletensile high-cycle fatigue tests to explore various laser deposition directions and surface roughnesses. The resulting SN curves provide insights into the high-cycle fatigue behaviour of LC materials. Additionally, SEM images were utilized to analyse the fatigue failure fracture characteristics. The experimental results reveal that cladding materials deposited parallel to the loading direction exhibit superior high-cycle fatigue performance. Fatigue fractures in the specimens generally originate from laser fusion defects, which not only reduce the lifespan of the specimen but also influence the failure location. Fatigue failure assessments of the laser-cladded materials were conducted via equivalent life diagrams, which revealed a high degree of correlation with the actual failure conditions. Existing fatigue design curves for base materials can be applied to the high-cycle fatigue performance design of laser-cladded 316L stainless steel, demonstrating a performance that surpasses the average level of steel butt welds.

Short Crack Behavior of an Additively Manufactured Ti–6Al–4V Alloy Under Ultrasonic High Cycle Fatigue Testing

ABSTRACTThe high cycle fatigue (HCF) behaviors of an additively manufactured (AM) Ti–6Al–4V alloy with fully lamellar microstructures processed electron beam powder bed fusion (EB‐PBF) and wire‐fed electron beam directed energy deposition (Sciaky) routes were compared. Ultrasonic fatigue (USF) testing at the stress ratio of R = −1 was applied to monitor the growth of small cracks initiated at surface micronotches. Crack growth rates lower than 10−8 (m/cycle) at ΔK = 6 MPa·m1/2 were measured in samples processed by both methods. The finer α lath thickness (~1 μm) of the Sciaky samples resulted in a slower fatigue crack growth rate than the EB‐PBF samples with coarser laths. The interaction of cracks with the lamellar microstructures was characterized by electron backscatter diffraction. Crack propagation largely followed the lath interfaces in the Sciaky samples, whereas cracks cut across colonies in the EB‐PBF samples. Different fatigue fracture surface characteristics were observed for the EB‐PBF and Sciaky samples.

Unnotched fatigue behavior of the laser powder bed fused and hot isostatic pressed Inconel 718 at 600 °C

The microstructure and mechanical properties of hot isostatically pressed (HIP) Inconel 718 additively manufactured using the laser beam powder bed fusion (LPBF) process were investigated at 600 °C, with emphasis on the high cycle fatigue behavior evaluated using the rotating bend fatigue tests, and elucidation of the role of γ” precipitate size on the fatigue resistance. Experimental results show that the unnotched fatigue strength (σf) of the peak aged alloy improves only by 7 % after HIP, as compared to that of the non-HIP peak aged alloy, despite a significant improvement in the ductility due to HIP. Over-aging the HIP alloy, however, led to a further enhancement (by ∼14 %) in σf. Fractographic analyses suggest that the fatigue crack initiation occurs from the intrusions and extrusions on the fracture surface of both versions of the aged alloy. Microstructural investigations reveal the presence of persistent slip bands (PSBs) with different morphologies in peak- and over-aged microstructures. A change in the deformation mechanism due to the size of precipitates was identified to be the reason for the formation of nano-grains (through dynamic recrystallization) within the PSBs of the alloy with a coarse γ” microstructure. In several {110} grains, ∼5 μm thick nanocrystalline grain zones formed on the specimen surface; they completely suppressed the formation of PSBs and enhanced the fatigue resistance of the HIP LPBF IN718 alloy in the over-aged condition.

New insights into physical origins of dynamic strain aging in Ti-2Al-2.5Zr alloy and influence on LCF and HCF behaviors

The multi-step strain aging tests were meticulously designed in this work to reveal the physical mechanisms of static strain aging (SSA) and dynamic strain aging (DSA) behaviors in Ti-2Al-2.5Zr alloy for the first time. It was revealed that the shuffling mechanism of interstitial oxygen atoms combined with the pinning effect of locally-generated cross-slip on the movement of screw dislocations were responsible for the occurrence of strain aging. Furthermore, the effects of DSA on the low-cycle fatigue (LCF) and high-cycle fatigue (HCF) properties were elucidated in Ti-2Al-2.5Zr alloy. Results showed that the sensitivity of DSA to cyclic loading was attributed to the generation of numerous residual edge dislocation segments through local cross-slip, facilitating the formation of dislocation veins which inhibited the formation of persistent slip bands (PSBs) and led to the significantly cyclic hardening. Finally, it was emphasized that the phenomenon of DSA should be carefully considered for the structural integrity assessment of Ti-2Al-2.5Zr alloy and several suggestions were provided.

Rotation bending high cycle fatigue behaviors of TC21 alloy with bimodal microstructure

The TC21 alloy has been extensively utilized in the aerospace structural components, making it crucial to investigate the fatigue damage mechanism of this alloy. In this study, a comprehensive investigation was conducted into the high-cycle fatigue damage mechanism of TC21 alloy under rotation bending, considering variations in primary equiaxed α (αp) phase contents and size in bimodal microstructure (BM). Results demonstrate that the TC21 alloy exhibits optimal strength-ductility and fatigue life at approximately 25 percent of the αp phase content. The content and dimension of the αp phase play a significant role in regulating the onset of fatigue fractures. Dislocation pile-up around the αp phase promotes the formation of microvoids and microcracks. Notably, when the content of the αp phase falls below 15 %, there is an increased influence from secondary α phase (αs) on crack initiation. Moreover, excessive amounts of αp coupled with decreased size lead to a reduction in fatigue life. The aforementioned factors contribute to an intensified concentration of stress, facilitate a more uniform path for crack extension, and expedite the rate of fatigue crack propagation.

High and very high cycle fatigue behavior of an additive manufactured hot-work tool steel

In the present study, the fatigue response of an additive manufactured H13 type hot-work tool steel is investigated across the High Cycle Fatigue (HCF) and Very High Cycle (VHCF) regimes. The primary focus encompasses the interpretation of fatigue strength models, the defect type analysis along with a detailed examination of crack initiation and growth mechanisms. Despite the tremendous development in AM technology, experimental data regarding advanced mechanical properties, and particularly fatigue behavior, are still limited. Here, microstructural analysis of a modified AMed H13 hot-work tool steel, a combination of HCF and VHCF testing methodologies implemented for the characterization of the fatigue behavior, as well as a thorough fractographic analysis of the fractured surfaces were performed. Results are compared with historical data of a conventionally ingot cast and forged grade to assess the influence of the AM process on the fatigue response of H13 hot-work tool steels. It proves to be comparable to the conventionally manufactured grade, showcasing the potential utilization of AM in the production of components used in high-demanding applications, and in hot work tooling applications. However, the type of critical defects identified in the AM grade was found to be process-induced, emphasizing the need to optimize process parameters to reduce both the number and size of defects and also to ensure component reliability and high performance in various industrial applications.

Tensile and High Cycle Fatigue Behavior of 316L and Fe-18Cr-22Mn-0.65N Stainless Steel at Stress Ratio of 0.1 at Room Temperature

Tensile and High Cycle Fatigue Behavior of 316L and Fe-18Cr-22Mn-0.65N Stainless Steel at Stress Ratio of 0.1 at Room Temperature

Very high cycle fatigue behavior of TC4 titanium alloy: Faceting cracking mechanism and life prediction based on dislocation characterization

This research analyzes the very-high-cycle-fatigue behavior of TC4 titanium alloy through fatigue tests at R = −1, −0.3, and 0.1. The results show that the S-N curves are all bilinear and exhibit three failure modes as surface slip failure, surface cleavage failure and interior cleavage failure. Transmission electron microscopy analysis reveals the dislocation structure in interior cleavage failure and suggests that the deformation mechanism of faceting cracking involves both anti-phase boundary shearing and stacking fault shearing mechanisms. It concludes that interior failure results from cleavage fracture of α grains due to dislocation slip. Based on the stress intensity factor of the maximum defect, a slip-cleavage competitive failure model was developed by considering factors such as control volume, defect size, external loading, and grain content, with good predictive results. Additionally, on the basis of the failure mechanism and crack propagation rate model, considering the coupled effects of crack tip blunting, stress ratio, Vickers hardness, and material fracture toughness on crack propagation, the crack propagation life prediction model is constructed. The life prediction model is further modified to be more conservative and accurate in predicting life by consideration the maximum defect size, providing important theoretical support and practical guidance for engineering applications.

High cycle fatigue behavior and strengthening mechanisms of laser powder bed fusion pure tantalum

The fatigue behavior and strengthening mechanisms of the laser powder bed fusion pure tantalum (LPBF-Ta), coupled with a fatigue life prediction model, were originally explored. The fatigue strength of LPBF-Ta fabricated at the optimal laser energy density (154.16 J/mm3) is 348 MPa (106 cycles), showing a remarkable improvement of about 80 % and 50 % compared with that of the annealed and cold worked commercially pure tantalum, respectively. The microstructural analysis identifies that cellular structures averaging 300 nm in size contribute 438.2 MPa to strengthening, serving as the main contributor to fatigue strength. The breaching of cell walls by dislocations, along with the activation of cross-slip, ensures plasticity and ultimately enhances fatigue strength. Besides, the analysis of the defects reveals that the internal lack of fusion pore can induce the secondary fatigue crack, resulting in a region of brittle crack propagation. Furthermore, a finite life prediction model is established by originally incorporating the size of the crack source defect, and it significantly improves the prediction accuracy of the fatigue life. These results provide guidance for the development of fatigue strengthening strategies for LPBF-Ta.

Effect of over-ageing on the tensile and torsional fatigue properties of the AlSi7Cu0.5 Mg0.3 precipitation-hardened cast aluminium alloy

The objective of this work is to evaluate the influence of over-ageing on the high cycle fatigue behaviour of the AlSi7Cu0.5Mg0.3 cast aluminium alloy. It is generally accepted that over-ageing has a large influence on the behaviour of these materials, however its effect on the fatigue strength is less understood. This work provides an experimental investigation of the effect of over-ageing on high cycle fatigue strength in both tensile and torsional loading conditions. It is shown that the torsional fatigue strength is more sensitive to over-ageing when compared to the tensile fatigue strength and that the fatigue defect sensitivity is negligible for torsional loads, in contrast to tensile loading conditions. The experimental results indicate that this is due to a change in the crack initiation mechanism, going from initiation in the matrix for torsion loads to initiation from casting defects for tensile loads. An original two-steps approach is proposed to rationalise the effect of over-ageing on the fatigue strength, with particular emphasis on decoupling the respective contributions from defects and the mechanical properties. This approach is used to build normalised Kitagawa-Takahashi diagrams that highlights the reduced defect sensitivity under tensile loads for the most severe over-ageing condition.

Effects of electrochemical machining on high-cycle fatigue of Inconel 718 blades

Blades made from Inconel718 (IN718) are generally machined using electrochemical machining (ECM), and the high-cycle fatigue (HCF) of such blades significantly impacts the service life of aeroengines. In this study, modal analysis was performed to obtain the blade modal shape and stress distribution at first-order frequency, after which blades were machined at different current densities (9.5A/cm2, 18.2A/cm2, 34A/cm2, 46.7A/cm2, 61.2A/cm2, 70.1A/cm2) and then subjected to detailed surface-integrity analysis and fatigue tests. No surface defects (e.g., intergranular corrosion, recast layers) were observed, the microhardness was unchanged, and new residual stress was not found to be introduced to the machined surfaces. The machined surfaces were uneven and contained micro-pits, and high current density contributed to better surface quality. At a constant load of 520 MPa, the blade machined at 70.1A/cm2 had the best fatigue life of 1.4×106. The blades fractured because of micro-pits, and as the surface quality of the blades improved, so did their fatigue performance. Therefore, the fatigue failure mechanism characterized in this work provides a reference for the HCF behavior of blades machined by ECM.

Comparative study on tensile and high cycle fatigue behaviour of 316L(N) SS hardfaced with Ni-Cr-B-Si alloy by GTA and laser cladding processes

In sodium-cooled fast reactors (SFR), 316L(N) SS grid plate is hardfaced with Ni-Cr-B-Si alloy to achieve higher wear resistance. Tensile and fatigue forces are acting at the interface between substrate and deposit due to different thermal expansion coefficients of those two materials, which can cause cracking of deposit and fracture during operation. Thus, it is very important to consider appropriate hardfacing method which can provide higher tensile and fatigue strength to avoid cracking/debonding at the interface. To find a solution to this problem, two hardfacing techniques, namely Gas Tungsten Arc (GTA) and Laser cladding (LC), are taken into consideration. Hardfaced specimens are prepared using each process on which tensile and high cycle fatigue tests are conducted. From the experimental testing, stress-strain and S-N curves are generated to predict the tensile and fatigue behaviour of specimens. Fractographic studies are conducted at fractured surfaces to understand the fatigue crack nucleation and propagation characteristics. The experimental results for both processes are compared. Tensile and fatigue strength of LC specimens are ∼11 % and ∼17 % less than those of GTA specimens due to its higher brittleness. Thus, GTA process is recommended as the efficient hardfacing process for grid plate of SFR.

Evaluation of microstructure and mechanical properties of additively manufactured Ti–5V–5Mo-5 Al-3 Cr alloy

Ti–5V–5Mo–5Al–3Cr (Ti-5553) is a near-beta titanium alloy commonly used in aerospace applications. It is currently being explored for additive manufacturing (AM), but the fatigue behavior of this AM alloy needs to be well-understood for adoption. This paper explores the tensile and high-cycle fatigue behavior of laser powder bed (LPBF) manufactured Ti-5553 that has been post-print heat treated with a beta anneal and age (BAA), with a focus on the microstructural evolution and effects of surface roughness and print defects. Fatigue lives of as-LPBF and BAA material are nearly identical and both are far below fatigue lives of conventionally manufactured Ti-5553. As-built samples contain columnar β grains with a [001] texture in the build direction with a negligible fraction of α phase confirmed by electron backscatter diffraction (EBSD). The BAA material contains HCP alpha-phase precipitates: grain boundary α, primary α, and secondary Widmanstätten α. Fatigue samples were printed in the vertical direction and tested with an as-printed and machined surface. Both the as-LPBF and BAA samples exhibit similar fatigue strengths despite their vastly different microstructures. Machined surfaces led to an increase in tensile strength, ductility, and fatigue strength. This work emphasizes the importance of heat treatment and minimization of flaws inherent to AM processing of near-beta Ti-5553.

High cycle fatigue behavior of bulk 6061Al prepared by cold spray-friction stir processing composite additive manufacturing

In this work, the high cycle fatigue behavior of bulk 6061Al prepared by cold spray-friction stir processing composite additive manufacturing (CFAM) was studied for the first time. The microstructure and fatigue fracture morphology of CFAM sample were characterized by scanning electron microscopy equipped with electron backscattering diffraction. The stress versus number of cycles of failure (S-N) curve for CFAM sample was established, and the fatigue crack growth behavior of CFAM sample was analyzed. The results showed that the microstructure of CFAM sample was denser and more homogeneous compared with cold spray (CS) sample, and the average grain size was refined to 3.3 μm due to dynamic recrystallisation. The dense, homogeneous and fine microstructure delayed the initiation and growth of fatigue cracks, and thus resulted in a 178% increase in fatigue strength in the CFAM sample over CS sample. The fatigue surface of the CFAM sample could be divided into fatigue source zone, crack growth zone, and transient fracture zone, showing typical fatigue fracture characteristics. The fatigue crack growth rate in the CFAM sample was significantly lower than that of CS sample for the same stress intensity factor range (ΔK). This was because the fine grains uniformly distributed in CFAM sample increased the proportion of grain boundaries and hindered the fatigue cracks growth. Therefore, CFAM is a promising technology for preparing bulk 6061 Al with excellent fatigue properties.

High cycle fatigue response of grain refined EUROFER97

The present paper has investigated the high cycle fatigue behavior of EUROFER97 steel submitted to a novel process consisting of cold rolling with reduction ratio of 80 % followed by a heat treatment at 650 °C for 1 h. This process had already proved to be highly effective under static loads leading to a significant improvement in yield stress. The fatigue tests have been performed with 0.2 load ratio at room temperature. Results indicate that the fatigue strength of the steel submitted to the novel treatment is comparable to that of the standard EUROFER97. Moreover, the fatigued samples underwent a microstructural evolution consisting of grain size increase and texture change due to the stress-driven instability of grain boundaries, especially LAGBs. The collapse of some boundaries involves partial annihilation and re-arrangement of dislocations, and grain coalescence. As a consequence of such microstructural change the material softens with hardness variations up to 8 %.

VHCF behavior and defect tolerance of modified bainitic 100Cr6 with a high retained austenite content

Since the fatigue life of high strength steels, e.g., roller bearing steel 100Cr6, depends on microstructural defects, an improvement of their defect tolerance can enhance the performance of components. To improve the defect tolerance, the retained austenite content can be increased. Thus, in this work the high cycle and very high cycle fatigue behavior of two modified laboratory variants of 100Cr6, which have an increased content (1.5 wt%) of Al and Si, respectively, were analyzed since these alloying elements lead to higher fractions of austenite. Moreover, an industrially available variant with 0.6 wt% Si was analyzed as a reference. All steels were investigated in the bainitic condition and had austenite contents of about 20 vol-%. However, the distribution and chemical composition of the austenite differed. The presented results demonstrate that the effect of retained austenite on defect tolerance is caused by i) the increased ductility and ii) the local deformation-induced phase transformation. To strengthen the effects of the austenitic phase, a finer distribution as well as a lower austenite stability are useful. Consequently, to evaluate the effect of retained austenite on the fatigue behavior the content, the distribution and the chemical composition of the austenitic phase must be considered.

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.