Low Cycle Fatigue Loading Research Articles

Elevated-temperature performances of Al-Si-Cu casting alloys for cylinder head applications

In this study, high-temperature properties of two newly developed Al-Si-Cu alloys (2Cu and 3.5Cu alloys) were investigated and compared to the commercial-grade A356 + 0.5Cu alloy (R alloy). 3.5Cu alloy exhibited the highest strength, outperforming R alloy by over 50 MPa at room temperature and by more than 20 MPa at elevated temperatures in ultimate tensile strength. However, R alloy demonstrated three to four times higher elongation than 3.5Cu alloy at room temperature, though this difference diminished at high temperatures. The minimum creep rate of 3.5Cu alloy was 2.4 times lower than that of 2Cu alloy and 14.5 times lower than that of R alloy, showing the superior creep resistance. Under low cycle fatigue loadings, the fatigue lifetimes of R and 2Cu alloys were similar, and slightly longer than that of 3.5Cu alloy. Conversely, in the high cycle fatigue regime, 3.5Cu alloy exhibited the highest fatigue resistance, followed by 2Cu and R alloys. The superior high-temperature performances of 3.5Cu alloy were attributed to the enhanced thermal stability of θ' precipitates compared to β' precipitates in R alloy, as confirmed during long-term thermal exposures at 250 and 300 °C. These findings suggest that 3.5Cu alloy is a promising candidate to replace the traditional A356 + 0.5Cu alloy for cylinder head applications.

Effect of Pt-Al coating on low-cycle fatigue behavior in a Ni-based single crystal superalloy at 760 °C

The effect of Pt-Al coating on low-cycle fatigue behavior of Ni-based single crystal superalloy at 760 °C was evaluated. The results show that Pt-Al coating does not change the cyclic stress response behavior of the Ni-based single crystal superalloy at 760 °C. Under the total strain amplitude from 0.6 % to 1.2 %, the cyclic stress amplitude value of Pt-Al coating samples is slightly lower than uncoated samples during cyclic deformation at the stable stage under the same applied total strain amplitude, and the fatigue life of Pt-Al coating samples is lower than uncoated ones, with an average fatigue life reduction of about 19.9 %. By the relation curve of comparing the cyclic strain amplitude with the reversals to failure, it is observed that the fatigue ductility coefficient ε′f of the Pt-Al coating sample is higher than the uncoated sample, the fatigue ductility index c and fatigue strength coefficient σ′f are lower than the uncoated sample, but the fatigue strength index b has little difference. It is found that the cyclic strength coefficient K′ and the cyclic strain hardening index n' of the Pt-Al coating sample are lower than the uncoated sample after fitting the curves of the relationship between cyclic stress amplitude and total strain amplitude. In addition, the cyclic stress amplitude of Pt-Al coating sample is slightly lower than uncoated sample under the same applied total strain amplitude. It was found by SEM that the cracks of both uncoated and Pt-Al coating samples initialized near the surface of the samples under low-cycle fatigue loading at 760 °C, and multiple crack sources began to spread into the substrate. It was found by TEM observation that at low strain amplitude (Δεt/2 = 0.6 %), the dislocations in both uncoated and Pt-Al coating samples mainly converged in γ, and a large number of dislocation debris gathered in the γ and dislocation entanglement was generated, while a small number of dislocations were observed to cut into γ'. The γ′ is seriously deformed and slightly rafted at Δεt/2 = 1.2 %, and a few dislocations are also observed in γ'.

Experimental investigations on combined high and low cycle fatigue: Material-level specimen design and strain response characteristics

The paper designs a novel material-level specimen and its dedicated fixture suitable for applying Combined high- and low- Cycle Fatigue (CCF) loads. Unlike full-scale or simulation specimens, the CCF specimen eliminates geometrically induced stress gradients in the test region. Experimental data on CCF life and strain responses of ZSGH4169 alloy are acquired under different CCF loads. The Maximum Strain within Each(MSE) CCF cycle is demonstrated to be independent of the Low-Cycle Fatigue (LCF) loads and High-Cycle Fatigue (HCF) stress amplitudes, but exhibits a correlation with the Cycle Ratio of HCF/LCF (Rf). The growth law of MSE changes from linear to logarithmic as Rf decreases. Strain amplitudes in the dwell stage, observed unaffected by Rf, are quantified as a function of LCF nominal stresses and HCF stress amplitudes. However, under a defined CCF load, strain amplitudes in the dwell stage remain constant. Strain peaks in the dwell stage in a single CCF cycle decrease in a power function with increasing HCF cycles.

Using physics-informed neural networks to predict the lifetime of laser powder bed fusion processed 316L stainless steel under multiaxial low-cycle fatigue loading

Axial-torsional Low-Cycle Fatigue (LCF) tests were conducted under strain control on Additively Manufactured (AM) 316L stainless steel using laser powder bed fusion. The tests covered various strain amplitudes under tension-compression, proportional, and pure shear loading paths. The AM 316L stainless steel exhibited cyclic softening and transgranular cracking under all the investigated loading conditions. The presence of deposition defects, predominantly the lack of fusion type, was identified as the main factor influencing the crack initiation and propagation, as well as the scatter in the fatigue lifetime. Therefore, to account for the damaging effects of these deposition related defects on fatigue lifetime, a novel physics-informed neural network was proposed. Subsequently, this neural network was combined with the critical plane approach, based on the tensile mode of failure, in order to predict the lifetime of AM 316L stainless steel. The predicted data exhibited a good correlation with the experimental results.

Preferential fatigue cracking at basal twist grain boundary (BTGB) in bimodal Ti-5Al-4V alloy: Dislocation activities and crack initiation

In recent years, (0001) twist grain boundaries (BTGBs) located in primary α grain clusters were identified as fatigue crack nucleation sites in different Ti alloys. In the present study, crack initiation was investigated in a bimodal Ti-5Al-4V alloy subjected to low-cycle fatigue and dwell-fatigue loadings at room temperature. The low fraction of primary α grains was not associated with a lack of sensitivity to BTGB cracking. Transmission electron microscopy and electron back-scattered diffraction were used to characterize BTGBs in the initial microstructure. The fatigue mechanisms were then analyzed with a focus on dislocation activity. αp grains adjacent to cracked BTGBs contained a high dislocation density. It was primarily composed of planar slip bands of <a> dislocations. In addition, <c+a> dislocations were noticed in the vicinity of cracked BTGBs. They supposedly pertain to crack tip plasticity during growth, and no evidence of a role of an incoming slip event in crack nucleation was obtained. Also, basal slip bands extending across adjacent grains were found to emerge from BTGBs. This feature provides an easier path for crack extension when growth along the grain boundary becomes difficult owing to a deviation from the basal plane. Atom probe tomography analyses evidenced V and Fe segregation at a grain boundary with a significant deviation from the BTGB configuration. This suggests a possible contribution of local solute segregation to the high cracking resistance of general αp / αp grain boundaries. This work provides new insights into the mechanisms involved in cracking of BTGB in Ti alloys subjected to cyclic loadings.

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.

Cyclic response and stability of shape memory alloy cables considering training, displacement history, and prestrain effects

Superelastic shape memory alloy (SMA) cables have been considered in the development of various seismic protection technologies. The cyclic nature of seismic loads necessitates a comprehensive understanding of the mechanical behavior of SMA cables under repeated loading conditions. As SMAs undergo repeated phase transformation cycles, alterations in their properties occur due to defects generated and modified during the transformation. When utilizing superelasticity, this response can be stabilized after numerous transformation cycles. In various applications, components made of SMAs undergo a stabilization process referred to as training to enhance the predictability of the alloy’s response. Despite the widespread acceptance of training cycles to achieve stable cyclic response, a well-defined protocol is lacking. This study investigates the effects of various factors, including training strain amplitude, repeated loading, low-cycle fatigue loading, loading at high strain amplitudes, displacement loading history, and prestrain on the cyclic response of a large-diameter SMA cable. A total of 14 SMA cable specimens are tested under various tensile loading conditions. The experimental results, including stress-strain curves and various response parameters such as peak stress, residual strains, energy dissipation capacity, and equivalent viscous damping are examined in detail. The results indicate that training SMA cables at a strain amplitude near the end of phase transformation plateau leads to a highly stable cyclic response. However, it is worth noting that, in comparison to untrained cables, training induces a softening effect in the cable response.

Cyclic deformation behavior and damage mechanism of 316H stainless steel under low-cycle fatigue loading at 650 °C

Low-cycle fatigue tests were conducted at 650 °C to investigate the cyclic deformation behavior and damage mechanism of 316H stainless steel at various strain amplitudes ranging from 0.2 % to 1.0 %. The relationship between macroscopic deformation properties and microscopic physical mechanisms was revealed based on the comprehensive analysis of local deformation misorientation and dislocation microstructure. Results showed that the 316H stainless steel presented non-Masing behavior at strain amplitudes lower than 0.6 %, and Masing behavior at strain amplitudes larger than 0.6 %, which was primarily attributed to the evolution of dislocation configurations. The crack initiation and propagation behavior at 0.2 % strain amplitude, characterized by the transgranular mode, was dominated by fatigue. However, the intergranular damage became dominant at the strain amplitude larger than 0.2 %, due to the intensified strain localization at grain boundaries. Moreover, the plastic strain energy was used for life assessment with the consideration of non-Masing behavior.

Strain distribution of a fir‐tree tenon/mortise structure under combined high and low cycle fatigue loads

AbstractThe fir‐tree tenon/mortise structure in areo‐engine suffers from the combined high and low cycle fatigue (CCF) loads during service. The structural integrity of the tenon/mortise structure is significantly affected by the local strain distribution, while the strain value under the CCF loads is difficult to acquire. In this study, a simulated specimen of tenon/mortise structure is designed, and the CCF test is carried out using a divided‐path loading fixture to avoid interference between the high cycle fatigue (HCF) loads and the low cycle fatigue (LCF) loads. The high speed digital image correlation (DIC) method is adopted to acquire the real‐time strain distribution during CCF test. According to the strain results, the critical position of the mortise and its strain variation are determined. The high cycle strain of the mortise is proportional to the vibration amplitude of the tenon. The experimental results can provide basis for strength and life assessment.

Fatigue life prediction of metal materials under random loads based on load spectrum extrapolation

The impact of random loading on the fatigue life of mechanical components contains numerous uncertainties. This study aims to enhance the precision of life prediction by developing mean and amplitude distribution models based on the road load spectrum and extrapolating the operational load beyond the threshold value in the time domain. Additionally, it considers the influence of high cycle fatigue (HCF) and low cycle fatigue (LCF) loads on the initiation life of metal cracks. To address this, a load correction factor is introduced, and critical stresses for high and low cycle loads are proposed. Furthermore, a two-dimensional programmed load spectrum is prepared, taking into account the mean and amplitude. The accuracy and rationality of the fatigue life model are validated through examples using 45# steel and 316L, while experiments on engine support are conducted to confirm the effectiveness and accuracy of the over-threshold extrapolation life prediction method under random loading.

Effect of Fe-Al intermetallics on fatigue properties of aluminum to steel dissimilar spot welds

Lightweight structures made of aluminum alloys and high strength steels are increasingly used for improving vehicle fuel efficiency. One barrier for joining aluminum and steel is the formation of brittle Fe-Al intermetallics that can have deleterious effects on joint ductility and strength under static loading conditions. However, it is unclear how the intermetallics affect the joint fatigue properties. In this study, the effect of intermetallics on fatigue properties of dissimilar metal joints between a 6xxx aluminum alloy and a high-strength steel is investigated on welds created by ultrasonic interlayered resistance spot welding (Ulti-RSW). Joint efficiency calculations are used to normalize the peak load so the fatigue properties of Ulti-RSW are compared with a wide range of joining processes in the literature. During fatigue testing the failure mode transitions from interfacial or button pull-out failure during low cycle fatigue loading (below 100,000 cycles) to through-thickness failure during high cycle (above 100,000 cycles). Based on the stress intensity factors calculated using a simple 2D fracture mechanics model, the transition in failure mode is attributed to the plastic deformation near the notch tip. Overall, this study shows that the intermetallics have little effect on the high-cycle fatigue properties of dissimilar spot joints.

Material characterization of iron-based shape memory alloys for use in self-centering columns

Iron-based shape memory alloys (FeSMAs) are emerging as a promising material for use in post-tensioning concrete structures to provide self-centering capabilities during a seismic event. Past experimental studies on FeSMA focused on strengthening or repairing existing structural components under gravity loading. In addition to the structural rehabilitation, FeSMA also have potential for use in self-centering columns subjected to seismic loads. However, the basic material properties, such as strength, ductility, recovery strain, actuation stress (i.e. prestress) stability, low-cycle fatigue resistance, and temperature dependence of FeSMA related to self-centering column applications have not been studied extensively to-date. To fill this knowledge gap and determine the feasibility of using FeSMA in self-centering columns, this study performed a comprehensive characterization and analysis of FeSMA both before and after actuation (i.e. thermal stimulation). The strength, ductility, energy dissipation, and recovery strain of FeSMA before actuation were tested at different temperatures from −40 °C to 50 °C. After actuation, the actuation stress, low-cycle fatigue resistance, and strain capacity of FeSMA were tested at different temperatures from −40 °C to 50 °C and prestrain levels from 4% to 30%, and under low-cycle fatigue loading with strain amplitudes from 0.5% to 1.0%. The results from this study demonstrated that FeSMA exhibit high ductility, cyclic actuation stress stability, and low-cycle fatigue resistance at temperatures from −40 °C to 50 °C. Furthermore, it was found that increasing the prestrain level can effectively increase the post-actuation strain amplitude at which the actuation stress reduces to zero. A prestrain level between 15% and 20% is recommended for application of FeSMA in self-centering columns. The research findings from this study demonstrated the feasibility of using FeSMA in self-centering columns subject to seismic loading.

Investigating the relationship between fracture entropy and stress amplitude in CFRP laminates under low-cycle fatigue loading

Fracture fatigue entropy (FFE) is considered to be independent of the loading amplitude in fatigue experiments, and this conclusion has been applied to fatigue life prediction of composites and metals with satisfactory prediction accuracy. However, the existing research work mainly focuses on high-cycle fatigue, and it is not clear whether the FFE is independent of the loading amplitude in low-cycle fatigue, which requires more in-depth research. Fatigue experiments were conducted on three CFRP laminates with different ply orientations, and the FFE values corresponding to low-cycle fatigue were obtained by thermographic analysis. The results show that the FFE value is no longer independent of the loading amplitude under low-cycle fatigue conditions. On the contrary, it decreases with the increase of fatigue loading amplitude and also varies with different ply orientations. The relationship between low-cycle fracture fatigue entropy and loading amplitude of composites with different ply orientations was analyzed and modeled, and a novel low-cycle fatigue life prediction method based on FFE was developed.

Low-cycle fatigue simulation of ductile materials using elasto-plastic gradient damage approach

This work presents a novel computational strategy based on gradient enhanced damage and cyclic yielding with nonlinear mixed hardening behaviour for simulating low-cycle fatigue of ductile materials. A new yield function is introduced which accommodates the cyclically evolving state variables during mixed hardening and the damage induced during the application of repetitive loads. The resulting constitutive relations are derived in an incremental form. The non-local strains facilitate the computation of incremental damage in the material. A finite element scheme is developed from the governing physics through full coupling between damage and cyclic-elastoplastic deformations. In order to obtain an accurate computational response, a stress-return mapping scheme is formulated for the damage-dependent yield function. The developed numerical strategy is investigated for specimens made of various ductile materials exhibiting elasto-plastic behaviour under low-cycle fatigue loads. The stress-strain hysteresis and cyclic softening computed by the present numerical framework agree well with experimental data available in literature. The low-cycle fatigue crack-growth results are also accurately captured for various fatigue loading conditions.

Probabilistic LCF life prediction framework for turbine discs considering random load history

Probabilistic LCF life prediction framework for turbine discs considering random load history

New approach to low-cycle fatigue lifetime prediction for deep-rectangular notched components with finite residual thickness: Experiment and simulation

The introduction of notches in engineering components often has detrimental effects on fatigue behavior. Current research on finite residual thickness is extremely limited, especially when dealing with more complex geometric shapes of notches. In this study, the low-cycle fatigue (LCF) life of cylindrical components with deep-rectangular notches were predicted based on the theory of critical distance (TCD) and the total stress field (TSF) method. The results indicated that the presence of stress concentration near the notch accelerated the initiation and propagation of cracks. Furthermore, finite element method (FEM) was conducted, revealing the need to comprehensively consider the stress distribution across the residual thickness zone (RTZ) for notched specimens. Through numerical method improvement and geometric modeling optimizations, the accuracy of fatigue lifetime prediction has been refined to within a margin of ± 1.5. Comparative simulations on notched specimens with various ratio of notch depth to residual thickness were conducted, characterizing the fatigue process zone (FPZ) near the notch root under LCF loading for Q345R steel, indicating that characteristic material parameter d* exhibits minimal fluctuations with changes in the notch size, while the corresponding local stress levels display a logarithmic upward trend, substantiating that fatigue lifetime decreases with larger notch sizes.

An approach to estimate the low cycle fatigue probabilistic curves of PBF-LB/M 316L steel from small size datasets using the remora optimization algorithm

The significant dispersion in fatigue properties is a prevalent attribute observed in metals manufactured by the Additive Manufacturing (AM). To ascertain the safety of components subjected to low cycle fatigue (LCF) loadings at a temperature of 550 °C, it is necessary to carry out a fatigue reliability assessment of AM metals. Nevertheless, the number of LCF life tests is limited owing to time-consuming nature of test and high total production cost of AM materials. Such a small size dataset cannot satisfy the criteria of the traditional reliability assessment method. This work aims to develop a novel method to evaluate the LCF reliability of 316L stainless steel manufactured by laser-based powder bed fusion of metals (PBF-LB/M) technology. Firstly, the Weibull model is coupled with the Coffin-Manson-Basquin relationship in order to characterize the dispersion of life data points at various strain levels. Secondly, reliability results from a small size dataset show a maximum relative error in fatigue life of less than 25 %, which is similar to results from a large size dataset and the traditional method using fatigue data from public sources. Among this step, the remora optimization algorithm is firstly applied to calculate the characteristic parameters of newly-proposed method. Thirdly, the LCF reliability of PBF-LB/M 316L based on the small size dataset is evaluated. The N95% is equivalent to 44 % of N50%. Finally, the PBF-LB/M 316L is compared with traditional 316L considering the reliability. The LCF properties of PBF-LB/M 316L is similar to the traditional 316L at 50 % reliability, however it’s slightly worse at 95 % reliability.

Strain energy density and entire fracture surface parameters relationship for LCF life prediction of additively manufactured 18Ni300 steel

In this study, the connection between total strain energy density and fracture surface topography is investigated in additively manufactured maraging steel exposed to low-cycle fatigue loading. The specimens were fabricated using laser beam powder bed fusion (LB-PBF) and examined under fully-reversed strain-controlled setup at strain amplitudes scale from 0.3% to 1.0%. The post-mortem fracture surfaces were explored using a non-contact 3D surface topography measuring system and the entire fracture surface method. The focus is on the relationship between fatigue characteristics, expressed by the total strain energy density, and the fracture surface topography features, represented by areal, volume, and fractal dimension factors. A fatigue life prediction model based on total strain energy density and fracture surface topography parameters is proposed. The presented model shows good accordance with fatigue test results and outperforms other existing models based on the strain energy density. This model can be useful for post-failure analysis of engineering elements under low-cycle fatigue, especially for materials produced by additive manufacturing (AM).

A reliability analysis and optimization method for a turbine shaft under combined high and low cycle fatigue loading

AbstractThe combined high and low cycle fatigue (CCF) loading condition and random uncertainty exert a considerable impact on the design of turbine shafts. To enhance the fatigue life and reliability, this research proposes a CCF reliability analysis and optimization method for turbine shafts. A CCF fatigue reliability analysis framework is established, which focuses on the quantification of CCF loading characteristics and random uncertainty. The consideration of CCF loading characteristics contain the loading frequency ratio of high cycle fatigue (HCF) to low cycle fatigue (LCF), the stress amplitude ratio of HCF to LCF, as well as their interaction. The consideration of random uncertainty contains material, geometry and load, and a surrogate model‐based method is introduced to improve the quantification efficiency. Through the validation by comparing with experimental data and traditional methods, the proposed method is with higher accuracy and efficiency. By integrating the proposed fatigue reliability analysis method with design optimization, optimal design values for the turbine shaft were identified. This method theoretically extends the shaft's CCF life and provides practical engineering guidance for its reliability analysis and design.

A modified nonlinear cumulative damage model for combined high and low cycle fatigue life prediction

AbstractAero‐engine turbine blades are subject to combined high and low cycle fatigue (CCF) loadings during operations. In this paper, a modified nonlinear cumulative damage model is developed based on linear damage accumulation theory and static toughness exhaustion to predict the CCF life of turbine blades and common blade materials. An interaction factor is created to reflect the integrated effect of high cycle fatigue and low cycle fatigue (HCF‐LCF). Available test data from TC4 alloy and other two alloy materials, together with two turbine blades are utilized to validate the robustness and accuracy of the proposed approach. Comparative results demonstrate that the proposed model holds better performance in life predictions under CCF loadings.