Reduction In Fatigue Life Research Articles

Reclaimed Asphalt Pavement in Concrete Pavements: Properties, Microstructure, and Design

Reclaimed asphalt pavement (RAP), when used as aggregate in concrete, is known to reduce the bulk concrete strength and modulus but not dramatically impact shrinkage, durability, or fracture properties, especially at lower replacement levels. This article presents an overview of RAP aggregates in concrete as it pertains to its effect on properties, microstructure, and pavement design. The mechanisms resulting in decreased strength and modulus for concrete containing RAP have been linked to: (1) the larger, more porous interfacial transition zone (ITZ) and (2) the dominance of an asphalt cohesion failure instead of an asphalt-cement adhesion failure. Despite these reductions in mechanical properties, multiple field studies have indicated that concrete with RAP can perform comparably to conventional concrete pavements, particularly when 10-15% RAP is used. The flexural capacity of concrete slabs with 22% RAP has shown similar behavior to virgin aggregate concrete given the similarities in fracture properties. Fatigue and accelerated pavement testing of rollercompacted concrete with high RAP contents (50-100%) have indicated a reduced fatigue life relative to plain concrete, requiring a slightly thicker design. Based on the literature, RAP aggregate replacement levels less than 25% can be used in concrete pavements without a significant change to the structural design.

Research on the Aging Characteristics of Simulated Asphalt Within Pavement Structures in Natural Environments.

The global asphalt production growth rate exceeded 10% in the past decade, and over 90% of the world's road surfaces are generated from asphalt materials. Therefore, the issue of asphalt aging has been widely researched. In this study, the aging of asphalt thin films under various natural conditions was studied to prevent the distortion of indoor simulated aging and to prevent the extraction of asphalt samples from road surfaces from impacting the aged asphalt. The aging of styrene-butadiene-styrene (SBS)-modified asphalt was simulated at four different locations on an asphalt road surface. The aging characteristics of asphalt binders across various structural layers were revealed using Fourier transform infrared spectroscopy (FTIR), atomic force microscopy (AFM), and linear amplitude scanning (LAS). The results indicate that the aging behavior of the asphalt functional group on the road surface differs from other conditions; the asphalt fatigue life of 4 months equates to the 16-month aging life of asphalt within the dense-graded asphalt road surface. After 8 months of aging, the surface smoothness of the asphalt was significantly compromised. Inside of the porous pavement, the asphalt functional group is more likely to interact with water molecules than inside the dense pavement with cracks, and the variations in roughness and the reduction in fatigue life are also more significant.

Methodology for Hydrogen-Assisted Fatigue Testing Using In Situ Cathodic Charging.

With hydrogen being a promising candidate for many future and current energy applications, there is a need for material-testing solutions, which can represent hydrogen charging under superimposed mechanical loading. Usage of high purity gaseous hydrogen under high pressure in commercial solutions entails huge costs and also potential safety concerns. Therefore, a setup was developed utilizing a customized electrochemical charging cell built into a dynamic testing system. With this setup, two heat treatment states of AISI 4140 (DIN 1.7225, 42CrMo4) with varying yield and ultimate tensile strength were characterized in constant amplitude tests. S-N (Woehler) curves differ between heat-treated states, and when comparing testing in air with in situ cathodic hydrogen-charged specimens, hydrogen proves to be detrimental to the material properties. For both states considered, the presence of hydrogen leads to a reduction in fatigue life. Fractographic analyses by scanning electron microscopy reveals that for in situ cathodic hydrogen-charged specimens, the crack initiation mechanisms change for the higher strength heat treatment state.

Experimental Investigation of Low‐Cycle Corrosion Fatigue Behavior of AA5059 Aluminum Alloy in Air and 3.5% NaCl Solution Environments

ABSTRACTThe shipbuilding industry is increasingly adopting aluminum alloys like AA5059 over traditional steel alloys to achieve lighter structures, enhanced environmental protection, and improved energy efficiency. Ship structures are frequently subjected to fatigue loading from combined wave‐induced stresses and corrosive effects. This study investigates the low‐cycle fatigue (LCF) behavior of AA5059 aluminum alloy in both air and a 3.5% NaCl solution to assess the impact of corrosion on fatigue life. LCF tests were conducted at strain amplitudes of ΔεT/2 = 0.3%–0.7%. The findings indicate a marked reduction in fatigue life in the NaCl solution compared with air, regardless of strain amplitude. Back (σb), effective (σeff) stresses were assessed using Dickson's approach, showing reduced back stress and increased effective stress in 3.5% NaCl, indicating diminished hardening and enhanced plastic deformation. Corrosion was observed to enhance plastic strain energy density (PSED), with specimens exhibiting massing behavior in air and non‐massing behavior in the corrosive environment. Fractographic analysis revealed corrosion pits, oxide formations, and secondary cracks in the crack initiation (CI), crack propagation (CP), and final fracture (FF) regions in NaCl. These findings on the low‐cycle corrosion fatigue performance of AA5059 provide valuable guidance for its application in shipbuilding, particularly in corrosive marine environments.

Crack Propagation and Fatigue Life Analysis of Wind Turbine Blades

This dissertation investigates the fatigue and fracture behaviour of wind turbine blades exposed to varying wind speeds and load intensities, aiming to enhance their durability and operational lifespan in sustainable energy systems. The increasing reliance on wind energy underscores the need for durable blades that can withstand cyclic loads and extreme environmental conditions, as fatigue and fracture failures significantly impact maintenance costs and reliability. This research specifically examines fatigue life and fracture initiation at wind speeds of 15 m/s and 60 m/s, analysing the effects of increased load intensities (30 MPa and 62 MPa). Finite Element Analysis (FEA) through ANSYS is employed to model fatigue and fracture dynamics, incorporating fatigue life prediction using S-N curves, stress analysis with von Mises stress, and crack propagation simulation via fracture mechanics principles, such as Paris’ Law. Results reveal a notable reduction in fatigue life with increased loads, evidenced by a drop from 9e09 to 7.9e08 cycles at 15 m/s, with comparable fatigue cycle reductions at 60 m/s. Fracture analysis identifies critical crack initiation points in high-stress areas, and simulations indicate the progressive nature of crack propagation under cyclic loads. These findings underscore the importance of integrating fatigue and fracture assessments in the design and maintenance strategies of wind turbine blades to enhance resilience and support the sustainable advancement of wind energy systems.

Fatigue of SFRC in compression: Size effect & autogenous self-healing

This review synthesizes prior research on size effect and autogenous self-healing in steel fiber-reinforced concrete (SFRC) under compressive fatigue. It explores the fatigue behavior of SFRC, focusing on fiber reinforcement’s role in post-cracking toughness, crack propagation, and fatigue endurance. The review demonstrates that larger SFRC specimens have reduced fatigue lives, attributed to increased elastic energy driving microcrack growth, aligning with classical size effect theory. Additionally, it highlights autogenous self-healing, where fatigue-induced microcracks release occluded water, promoting rehydration and calcium carbonate precipitation, which enhances residual strength. The interaction between size effect, fiber content, and self-healing is examined, offering insights into improving SFRC’s durability under cyclic loading. These findings have practical implications for designing SFRC structures subjected to compressive fatigue, such as wind turbine towers and railway slabs.

Advanced Materials Methods Driving New Life in Critical Infrastructure

Fatigue damage is a major threat to many hydraulic steel structures (HSS). HSS experience fatigue loading during operation and are exposed to harsh environmental conditions that reduce fatigue life. The common methods to inspect and repair HSS is time-consuming and costly. Studies investigating the use of bonded Carbon and Basalt fiber reinforced polymer (CFRP, BFRP) to repair fatigue cracks in HSS are lacking. The main objectives of this study was to increase the bonding of FRP, investigate the effectiveness of different fiber-reinforced polymers, and perform experiments on different retrofitting configurations. In this study, eight large-scale center-cracked panels were tested under mode I loading under different environmental conditions, repair materials, and retrofitting configurations. Results indicated that the use of both CFRP and BFRP are both effective at extending fatigue life. Steel retrofitted with full patches of BFRP that cover the crack can reached infinite fatigue life. This article will conclude with several examples where FRP’s have been used to repair lock gates.

Effect of platform design of dental implant abutment on loosening and fatigue performance

Under the influence of daily occlusal forces, mechanical complications such as loose connections and fatigue damage are significant factors contributing to dental implant failure. The structural design of implant components is crucial in enhancing the long-term durability of implant systems. This research explores the impact of the platform structure of the abutment on connection loosening and fatigue properties. Four abutments with varying platform structures were designed and produced. The study involved testing and comparing screw loosening behavior before and after loading, as well as evaluating static load strength and fatigue characteristics. Observations were made on abutment surface wear and fatigue sections. A three-dimensional model was utilized to confirm damage location using the finite element method. Results indicate that the abutment’s platform structure enhances anti-loosening performance and static failure load, while reducing fatigue life. Additionally, the position of fatigue fracture in the abutment is influenced by the load magnitude. The finite element analysis (FEA) findings align with the results of the static load tests.

How does turbulence intensity affect the fatigue life of composite airfoils based on existing CFD and experimental data?

This research investigates the effect of airflow turbulence intensity on the fatigue life of composite airfoil structures in aerospace engineering. Using advanced Computational Fluid Dynamics (CFD) simulations, this study provides a comprehensive analysis of how varying levels of turbulence intensity—ranging from mild (5%) to severe (30%)—impact the mechanical degradation and fatigue performance of carbon-fiber-reinforced polymers (CFRPs) used in airfoil designs. The research quantifies the relationship between turbulence levels and changes in stress distribution, highlighting critical points of fatigue crack initiation and subsequent propagation. The study includes detailed comparisons of CFD results to experimental data to validate the predictive models and discusses how localized stress fluctuations under high-intensity turbulence accelerate the onset of fatigue failure. We present significant findings that demonstrate a non-linear relationship between turbulence intensity and the reduction in fatigue life, suggesting optimal design modifications for enhanced durability. Furthermore, this paper explores current challenges in merging CFD data with real-world fatigue testing and proposes advanced techniques such as adaptive mesh refinement and hybrid simulation models to improve predictive accuracy and computational efficiency in future research.

Role of inclusion clusters on fatigue crack initiation in powder metallurgy nickel-based FGH96 superalloy

Inclusion clusters with a size of several tens of micrometers were found to be inclined to early crack initiation, resulting in an abnormally reduced fatigue life. Fatigue tests were conducted to elucidate crack initiation behaviors of inclusion clusters in nickel-based powder metallurgy (P/M) FGH96 superalloy. The inclusion clusters with varying sizes and shapes located at grain boundaries are composed of Al2O3, MgO and ZrO2 particles. The inclusion cluster with large size within 25-35 μm, small average particle distance within 0-4 μm and large orientation relative to loading direction within 35-66° will be more likely to cause crack initiation. In particular, the inclusion clusters with large size and high aggregation degree experience extruding during processing and subsequent heat-treatments due to the difference in thermal expansion coefficient with the matrix behave multiple cracking before fatigue loading, thereby facilitating crack initiation in the surrounding matrix grains. Moreover, as the main cracking part of inclusion clusters, the Al2O3 particles exhibit self-cracking and interface debonding, owing to higher hardness and poorer deformation coordination degree with matrix compared to other component inclusion particles.

Long-Term Mechanical Deterioration Trends and Mechanisms of SBS-Modified Asphalt Mixtures

Understanding the long-term performance deterioration trends and mechanisms of asphalt pavement is crucial for effective maintenance strategies. This study characterizes and correlates the multi-scale performance deterioration of a 14-year asphalt pavement. Air void measurements, indirect tensile (IDT) fatigue testing, Fourier transform infrared spectroscopy (FTIR), and dynamic shear rheometer (DSR) testing were conducted on pavement cores and recovered binder. Multiple regression analysis was then performed on various performance indicators. Laboratory results indicate that the chemical composition and viscoelastic properties of SBS-modified binders evolve rapidly in the first few years, followed by a relatively stable aging rate. After 14 years, the mechanical and rheological properties of lower-layer mixtures deteriorate to a similar degree as the surface layer. Correlation analysis revealed that the residual strength of the mixture is more influenced by air voids, while reductions in fatigue life are primarily driven by binder aging. These findings highlight the necessity of applying preventive maintenance within the first 3–5 years to rejuvenate the surface asphalt and rehabilitate both the surface and underlying layers after long-term service.

Investigating the Anisotropic Mechanical Behaviour of Steel Fibre-Reinforced Aluminium-Base Composites

Base metals are often reinforced with fibres to improve their mechanical behaviour; however, it is imperative to decide the range of fibres orientation that would yield favourable strength. In this work, using sand casting method, aluminium is reinforced with galvanized steel fibres at different orientations with the aim of investigating the anisotropic mechanical behaviour of the composites. The fibre orientations considered are 0°, 30°, 60° and 90°; while the mechanical properties evaluated are impact energy, tensile, compressive and fatigue properties. Unreinforced aluminium exhibits impact energy, elongation-at-fracture, ultimate tensile strength, and maximum compressive strength of 5.15 J, 15.88%, 72.56 MN/m2, and 231.13 MN/m2, respectively. With deviation of composite fibre orientation from 0° to 30°, 60° and 90°, impact energy decreases from 8.68 to 5.56, 4.75 and 4.61 J; elongation-at-fracture decreases from 24.58 to 17.91, 12.20 and 11.87%; ultimate tensile strength decreases from 132.70 to 89.17, 63.67 and 60.34 MN/m2; and maximum compressive strength decreases from 310.66 to 251.06, 226.91 and 209.93 MN/m2. At fatigue stress amplitude of 850 MN/m2, the fatigue life of unreinforced specimen is 26 numbers of cycles-to-failure; while the deviation of composite fibre orientation from 0° to 30°, 60° and 90° yielded reduction in fatigue life from 64 to 36, 20 and 14 numbers of cycles-to-failure. Also, reduction in fatigue stress amplitude was found to increase the fatigue life of the specimens. The fatigue limit (or endurance limit) of unreinforeced specimen, and composite specimen having 0°, 30°, 60° and 90° fibre orientations are found to be 40, 70, 45, 35 and 25 MN/m2, respectively; and the corresponding fatigue life are observed to be 35480, 199518, 112195, 10021 and 5297 numbers of cycles-to-failure, respectively. The findings in this work show that specimens with 0° fibre orientation have the highest endurance of deformation before fracture, followed by specimens with 30° fibre orientation, unreinforced specimens, specimens with 60° fibre orientation and specimens with 90° fibre orientation. This could be attributed to the fact that 0° fibre orientation offers continuous reinforcement spanning the longitudinal axis of the specimens, while fibre orientation from 30° to 90° offer areas of different degrees of shear stress concentration at fibre-matrix contacts aiding fibre-matrix debonding and crack propagation. In conclusion, this work shows that orientation of steel fibre reinforcement in aluminium matrix could be varied to achieve ranges of mechanical properties and performance needed for different practical applications.

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.

Stress fracture of bone under physiological multiaxial cyclic loading: Activity-based predictive models

While it is known that excessive accumulation of fatigue damage from daily activities contributes to fracture, a model of bone failure under physiologically relevant multiaxial cyclic loading needs to be developed in order to develop effective management strategies for stress or fatigue fractures. The role of strain-induced damage from repetitive loading is a strong candidate for such a model, as cycles of mechanical loading leading to failure can be measured directly. However, this approach has been limited by the restrictions of uniaxial loading models, which often overestimates the fatigue life of bone and suggests that bone will only break well beyond the realistic limits of exercise. To address this gap and develop a physiologically relevant model, our study leverages the power of four commonly used engineering failure criteria as a model for multiaxial loading using a cohort of human tibiae from cadaveric donors (age range 21–85 years old). Four failure criteria (Von Mises, Tsai-Wu, Findley critical plane, and maximum shear strain) were found to be effective in vitro models of tibial fracture when age groups of donors were combined (r2 > 0.84) and stratified (younger: 21–52-years-old versus older: 57–85-years-old) (r2 > 0.83) (p < 0.001). Each failure criterion displayed distinctly lower fatigue curves for the older age group. The maximum shear strain model was used to determine the efficacy of this approach to predict fatigue fractures in humans using published in vivo data from human volunteers. Consistent with in vivo observations in general population, the model demonstrated failure at 5000 to 200,000 loading cycles depending on activities such as jumping, sprinting, and walking, with a 3-fold reduction of fatigue life in older donors. These findings dramatically improve estimates of fatigue life under repetitive loading and demonstrate how age-related changes in bone significantly increase its propensity for fatigue-induced fractures.

Effect of Internal Technological Defects and Loading Waveform on Structural Composite Fatigue Life

This paper explores the effect of internal technological defects on the fatigue life of carbon fiber reinforced plastic (CFRP) under simple loading waveforms. One conducted experiments on CFRP specimens with embedded artificial defects, including delamination’s (circular dry-spot) and wrinkling. Following quasi-static tests, one developed a fatigue testing program using triangular and sine waveforms. The findings indicate that these simple waveforms do not significantly affect the fatigue resistance of defect-free CFRP or CFRP with internal technological defects. The presence of the wrinkling defect significantly diminishes the fatigue resistance of CFRP. However, constructing fatigue life curves in relative terms reveals that the reduction in fatigue properties is directly related to a decrease in strength properties. In the case of delamination (dry-spot) defects, a reduction in fatigue life by approximately 2.5 times was observed across the tested range.

Deformation and microregion fracture mechanisms in type 316L welded joint under isothermal and thermo-mechanical fatigue loadings

Isothermal (IF) and thermo-mechanical fatigue (TMF) tests were conducted on 316L welded joints to investigate the effects of phase angle (in-phase (IP), clockwise-diamond (CD), and out-of-phase (OP)) and mechanical strain amplitude (±0.4 %, ±0.5 %, ±0.6 %) on deformation and microregion fracture mechanisms. Results reveal that increasing strain amplitude induces a higher softening rate, reduced fatigue life, and more pronounced dynamic strain aging (DSA). Nevertheless, there is a complicated discrepancy in the cyclic deformation between various phase angles. At high strain amplitudes, local embrittlement along the austenite/δ-ferrite interface induces cracking in the weld metal (WM) under both IF and TMF loadings, with TMF life increasing with phase angle. At a lower strain amplitude of 0.4 %, however, fracture location migration and different TMF life were observed. Microstructural analysis reveals that during TMF a lower strain amplitude of 0.4 %, the microstructure in both base metal (BM) and WM evolves from simple planar structures to low-energy substructures, characterized by an increase in kernel average misorientation, geometrically necessary dislocations, and low-angle grain boundaries, together with a reduction in high-angle grain boundaries and twin boundaries. In the WM, increasing phase angle tends to reduce dislocation density and reproduces planar dislocation structures due to enhanced DSA, thereby lowering cellular structure maturity. Conversely, in the BM, dislocation proliferation and interaction intensify, enhancing cellular structure maturity and de-twinning effect, which reduces BM fracture resistance and causes fracture migration from the WM to the BM. Moreover, active DSA under CD loading improves deformation resistance in both microregions, prolonging fatigue life and contributing to the observed different TMF life.

Alpha-case promotes fatigue cracks initiation from the surface in heat treated Ti-6Al-4V fabricated by Laser Powder Bed Fusion

This research investigates the effect of the formation of an oxygen-stabilised titanium alpha layer – called alpha-case at the surface – on the fatigue properties of Ti-6Al-4V (Ti64) alloy components produced by Laser Powder Bed Fusion (L-PBF). Three post processing heat treatments with different controlled atmospheres were carried out on samples with as-built surfaces to evaluate how differences in alpha-case layer thickness and hardness affect the material’s susceptibility to surface embrittlement and its overall fatigue performance. The investigation includes bulk and subsurface microstructural analysis, surface characterisation by X-ray computed tomography (XCT), and fatigue testing. Key findings show that alpha-case layers can reduce the fatigue resistance of L-PBF fabricated Ti64. The presence of a 70±3 µm thick alpha-case layer was found to promote crack initiation. This is emphasised by a higher density of initiated cracks, thus leading to a reduction in fatigue life. Conversely, thinner alpha-case layers were found to have a reduced impact on the fatigue performance, highlighting the critical role of post processing heat treatments in modulating the fatigue resistance of the material. The use of XCT to characterise the surfaces of the specimens in 3D confirms that fatigue cracks primarily initiate at surface notches, highlighting the predominance of as-built surfaces over microstructure in determining the fatigue resistance of L-PBF Ti64 components.

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'.

Fatigue Life and Stress Analysis of a Single Cylinder Four Stroke Crankshaft

This paper focuses on the optimization of a crankshaft using ANSYS software in terms of weight and strength. The initial designs of the crankshaft, piston, and connecting rod were created using SolidWorks. The force generated by the gas during the combustion process was calculated to be 12017 N. Next, the SolidWorks assembled system was imported into ADAMS View software for simulation, which revealed a time-variant force of the crankpin of 14049 N. The calculated value was verified with results obtained from analytical calculations, showing a deviation of 0.23%. Finite element analysis was done for the crankshaft using ANSYS transient structural after applying loadings and boundary conditions. The optimization process aimed to minimize the crankshaft's weight while maintaining its strength and durability. The results of the ANSYS simulations showed a weight reduction of 2.5% from the original 2.983 kg to 2.907 kg, while maintaining the required strength and durability. The optimized crankshaft was compared to its original design in terms of fatigue life, weights, and stresses. The maximum von Mises stress was reduced by 16%, shear stress by 3.5%, and deformation by 3.5%, which were validated through analytical calculations. The crankshaft analysis resulted in a significant increase in fatigue life, calculated to be infinite under the given conditions. To conclude, the objective to optimize the crankshaft for performance and efficiency was achieved, demonstrating a 2.5% weight reduction and substantial improvements in fatigue life and stress distribution, proving the effectiveness of ANSYS software for the design optimization process.

Experimental Study of Reaming Sizes on Fatigue Life of Cold-Expanded 7050-T7451 Aluminum Alloy

The split-sleeve cold expansion technology is widely used in the aerospace industry, particularly for fastening holes, to enhance the fatigue life of components. However, to ensure proper assembly and improve surface integrity, reaming of the cold-expanded holes is necessary. This study investigates the effects of cold expansion and reaming processes on the fatigue performance of 7050-T7451 aluminum alloy. Fatigue tests, residual stress measurements, and microstructural analyses of the hole edges were conducted on specimens with four different hole diameters after cold expansion and reaming. It was found that the depth of reaming significantly affects fatigue life. During the cold expansion process, the compressive residual stress formed around the hole effectively improves fatigue performance. The experiments demonstrated that reaming by 0.2 mm to 0.4 mm helps eliminate minor defects, thereby improving fatigue life. However, reaming beyond 0.5 mm may lead to stress relief and the removal of dense grains at the hole edges, reducing fatigue life. Therefore, determining the optimal reaming size is crucial for enhancing the reliability of aerospace fasteners.