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Metals
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Failure of Metals: Fracture and Fatigue of Metallic Materials
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Failure of Metals: Fracture and Fatigue of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: 30 April 2025 | Viewed by 4601

Special Issue Editors

Dr. Zhixin Zhan

E-Mail Website
Guest Editor
School of Aeronautic Science and Engineering, Beihang University, Beijing 100191, China
Interests: damage mechanics; finite element analysis; mechanics of materials; solid mechanics; mechanical behavior of materials; failure analysis; plasticity; finite element modeling; fatigue of materials; fatigue; fracture analysis
Special Issues, Collections and Topics in MDPI journals
Dr. Chuanqi Liu

E-Mail Website
Guest Editor
State Key Laboratory of Nonlinear Mechanics, Institute of Mechanics, Chinese Academy of Sciences, Beijing 100090, China
Interests: multiphase/multiscale analysis of granular materials; structured mesh modeling; engineering numerical methods
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Fracture and fatigue are two critical failure modes that can significantly affect the integrity and reliability of metallic materials. Studying these modes in such materials is necessary for ensuring safety, enhancing reliability, optimizing design, predicting lifespan, conducting failure analysis, developing materials, and complying with industry regulations. It is a critical area of research and engineering that impacts numerous industries and plays a vital role in the advancement and application of metallic materials. The difficulties faced in the fracture and fatigue of metallic materials are not only due to the complex material behavior but also the multiscale nature, environmental effects, and experimental limitations. Therefore, the development of advanced fracture and fatigue methods, prediction methods, and assessment technologies in industry would result in substantial benefits.

We plan to launch this Special Issue of Metals to discuss the state of the art and future trends in the fracture and fatigue of metallic materials. The objective of this Special Issue is to provide insights into the underlying mechanisms of fracture and fatigue in such materials, fostering the development of more durable and reliable metal structures. Topics of interest include, but are not limited to, the microstructural aspects influencing crack initiation and propagation, the role of defects and impurities, the effect of loading conditions and stress concentrations, and the influence of environmental factors. The issue also covers advanced experimental and computational techniques used to study fracture and fatigue, including fracture mechanics, fatigue life prediction models, and nondestructive evaluation methods.

Moreover, a wide range of metallic materials will be discussed, including steels, aluminum alloys, titanium alloys, and other commonly used engineering alloys. Case studies and practical applications will be presented which relate to failure analysis and prevention in different industries, such as aerospace, automotive, energy, and structural engineering.

Dr. Zhixin Zhan
Dr. Chuanqi Liu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • failure analysis
  • fracture mechanics
  • fatigue behavior
  • microstructure
  • defects
  • material defects
  • experimental testing
  • computational modeling
  • life prediction models
  • multiscale modeling

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Published Papers (4 papers)

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Research

28 pages, 34197 KiB  
Article
The Influence of the Ratio of Circumference to Cross-Sectional Area of Tensile Bars on the Fatigue Life of Additive Manufactured AISI 316L Steel
by Luka Ferlič, Filip Jerenec, Mario Šercer, Igor Drstvenšek and Nenad Gubeljak
Metals 2024, 14(11), 1246; https://doi.org/10.3390/met14111246 - 2 Nov 2024
Viewed by 599
Abstract
The static and dynamic loading capacities of components depend on the stress level to which the material is exposed. The fatigue behavior of materials manufactured using additive technology is accompanied by a pronounced scatter between the number of cycles at the same stress [...] Read more.
The static and dynamic loading capacities of components depend on the stress level to which the material is exposed. The fatigue behavior of materials manufactured using additive technology is accompanied by a pronounced scatter between the number of cycles at the same stress level, which is significantly greater than the scatter from a material with the same chemical composition, e.g., AISI 316L, but produced by rolling or forging. An important reason lies in the fact that fatigue cracks are initiated almost always below the material surface of the loaded specimen. Thus, in the article, assuming that a crack will always initiate below the surface, we analyzed the fatigue behavior of specimens with the same bearing cross section but with a different number of bearing rods. With a larger number of rods, the circumference around the supporting part of the rods was 1.73 times larger. Thus, experimental fatigue of specimens with different sizes showed that the dynamic loading capacity of components with a smaller number of bars is significantly greater and can be monitored by individual stress levels. Although there are no significant differences in loading capacity under static and low-cycle loading of materials manufactured with additive technologies, in high-cycle fatigue it has been shown that the ratio between the circumference and the loading cross section of tensile-loaded rods plays an important role in the lifetime. This finding is important for setting a strategy for manufacturing components with additive technologies. It shows that a better dynamic loading capacity can be obtained with a larger loading cross section. Full article
(This article belongs to the Special Issue Failure of Metals: Fracture and Fatigue of Metallic Materials)
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15 pages, 11182 KiB  
Article
Failure Analysis of the Half-Shafts Belonging to a Three-Wheeled Electric Vehicle
by Inês Mendes, J. Henrique Lopes, Eduardo Matos Almas and Luís Reis
Metals 2024, 14(6), 727; https://doi.org/10.3390/met14060727 - 19 Jun 2024
Viewed by 883
Abstract
In the electric vehicles studied, the driven wheels and the differential, which are responsible for the transfer of power and rotational motion, are connected by half-shafts. The failure of two half-shafts in the rear gearbox of a three-wheeled electric vehicle, popularly known as [...] Read more.
In the electric vehicles studied, the driven wheels and the differential, which are responsible for the transfer of power and rotational motion, are connected by half-shafts. The failure of two half-shafts in the rear gearbox of a three-wheeled electric vehicle, popularly known as a Tuk Tuk, is examined and evaluated in this research. Therefore, the primary goal of this work is to look at the factors that contribute to the failure of the aforementioned components. Visual examination and fractographic analysis were performed utilizing optical and scanning electron microscopes to investigate the half-shafts’ mode of failure. Samples from both half-shafts were obtained for tensile testing, metallographic examination, chemical composition analysis, and fracture surface analysis. According to visual examination, reversed bending fatigue, occurring simultaneously with torsion loading, caused the fracture in the half-shaft to the left of the differential (rear view). Analysis of the fracture surface of the half-shaft to the right of the differential revealed that it resulted mainly from bending fatigue loading. Moreover, regarding the mechanical design safety of the half-shafts, calculations were performed considering different trajectories, limit speeds, and different design criteria. Finally, some recommendations are drawn to improve the design safety of this mechanical component. Full article
(This article belongs to the Special Issue Failure of Metals: Fracture and Fatigue of Metallic Materials)
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20 pages, 11765 KiB  
Article
Failure Mechanism of Rear Drive Shaft in a Modified Pickup Truck
by Zhichao Huang, Jiaxuan Wang, Yihua Hu, Yuqiang Jiang, Yong Xu and Xiongfei Wan
Metals 2024, 14(6), 641; https://doi.org/10.3390/met14060641 - 28 May 2024
Cited by 1 | Viewed by 874
Abstract
This paper investigates the failure mechanism of the rear drive shaft in a modified pickup truck which had operated for about 3000 km. The investigation included macroscopic and microscopic evaluation to document the morphologies of the fracture surface, measurement of the material composition, [...] Read more.
This paper investigates the failure mechanism of the rear drive shaft in a modified pickup truck which had operated for about 3000 km. The investigation included macroscopic and microscopic evaluation to document the morphologies of the fracture surface, measurement of the material composition, metallographic preparation and examination, mechanical testing, and finite element modelling and calculations. The results obtained suggest that rotation-bending fatigue was the primary cause of the drive shaft failure. The crack initiation is located in the root of the machined threads on the drive shaft surface and expanded along the side of the machining line surface. The main cause of fatigue cracks is attributable to a high stress concentration owing to a large unilateral bending impact under overload. Meanwhile, the bidirectional torsional force also produces a higher stress concentration and thus accelerates the fatigue crack to expand radially along the surface. Furthermore, the hardness of the central section of the drive shaft was marginally below standard. This deficiency results in harm to the bearings and other mechanical components, as well as expediting the enlargement of cracks. Finite element analysis revealed significant contact stress between the bearing and drive shaft, with stress levels exceeding the fatigue limit stress of the parent material. This highlights the need for reevaluation of the heat treatment process and vehicle loading quality to enhance the drive shaft’s longevity. Full article
(This article belongs to the Special Issue Failure of Metals: Fracture and Fatigue of Metallic Materials)
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21 pages, 148830 KiB  
Article
Fatigue and Impact Behavior of Friction Stir Processed Dual-Phase (DP600) Steel Sheets
by Mumin Yilmaz, Imren Ozturk Yilmaz and Onur Saray
Metals 2024, 14(3), 305; https://doi.org/10.3390/met14030305 - 4 Mar 2024
Cited by 1 | Viewed by 1282
Abstract
This study investigates the impact of friction stir processing (FSP) on the deformation behavior of 1.1 mm-thick DP600 steel sheets under both static and dynamic loading scenarios, with a focus on the automotive applications of the material. During the process, the large plastic [...] Read more.
This study investigates the impact of friction stir processing (FSP) on the deformation behavior of 1.1 mm-thick DP600 steel sheets under both static and dynamic loading scenarios, with a focus on the automotive applications of the material. During the process, the large plastic shear strains imposed by FSP resulted in a maximum temperature of 915 °C, leading to a morphological transformation of the martensite phase from well-dispersed fine particles into lath martensite and grain refinement of the ferrite phase. DP600 steel showed an almost two-fold increase in static strength parameters such as the hardness value, yield strength, and ultimate tensile strength. As-received and processed DP600 steel exhibited a plastic deformation behavior governed by strain hardening. However, uniform elongation and elongation to failure after FSP took lower values compared to those of the as-received counterpart. Following the improvement in the static strength of the steel, the fatigue strength of the steel increased from 360 MPa to 440 MPa after the FSP. The finite-life fatigue fracture surfaces of the as-received samples were characterized by the formation of fine bulges due to the variation in the crack propagation path in the vicinity of the martensite particles/clusters. After FSP, the transformation of the martensite particles into coarser lath martensite also transformed the fracture surface into a step-like morphology. The microstructural evolution after FSP caused a decrease in the absorbed impact energy and maximum striker reaction force from 239 J and 37.6 kN down to 183 J and 33.6 kN, respectively. However, the energy absorption capacity of the processed steel up to failure was higher than the absorbed energy value of the as-received steel at the same impact displacement. The simultaneous decrease in both impact energy and reaction force is attributed to the higher cracking tendency of the processed microstructure due to the lower volume fraction of the ferrite phase. The experimental results reported in this study mainly show that FSP is an easy-to-apply and functional solution to significantly improve the static and cyclic strength of DP600 steel. However, it is clear that the reduced total impact energy absorption capacity after FSP may be taken into account in design strategies. Full article
(This article belongs to the Special Issue Failure of Metals: Fracture and Fatigue of Metallic Materials)
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