Search Results (92)

This study investigated a 460 MPa marine engineering steel’s microstructure and low-cycle fatigue (LCF) behavior along the thickness direction. The results showed that the low-cycle fatigue life was reduced from 9681, 4395, 2107, 1020, 829 to 7222, 1832, 1015, 630, 242 with the specimen taken from the surface to the middle of steel plate, increasing grain size and decreasing the content of high-angle grain boundaries (HAGBs). All specimens showed notable cyclic hardening and softening. This was related to the dislocation movement, interaction, accumulation, annihilation, and dynamic recovery during fatigue tests. Furthermore, the crack propagation paths in the fatigue specimens were also observed and discussed. Finally, the Basquin and Coffin–Manson relationships were used to suggest a prediction model for the LCF life at strain amplitudes ranging from 0.4% to 1.2%, and the anticipated outcomes agreed well with the test results. Full article

Additive manufacturing has been widely adopted in industry as an alternative to traditional manufacturing processes for complex component production. In fact, a diverse range of materials, particularly polymers, can be processed using 3D printing for biomechanical applications (e.g., prosthetics). However, in-depth evaluation of these materials is necessary to determine their suitability for demanding applications, such as those involving cyclic loading. Following previous work that studied Polylactic Acid (PLA) and Polyethylene Terephthalate Glycol-modified (PETG) under experimental fatigue testing, this study examines the fatigue behaviour of other current 3D-printed polymeric materials, namely Acrylonitrile Styrene Acrylate (ASA), Polycarbonate (PC), Polyamide 12 (Nylon 12), and Polycarbonate–Acrylonitrile Butadiene Styrene (blend) (PC-ABS), for which fatigue data remain limited or even non-existent. The findings revealed performance differences on Tensile Strength (σ_R), Young’s Modulus and Ultimate Strain among tensile specimens made from these materials and characterised S-N curves for both high-cycle (HCF) and low-cycle (LCF) fatigue regimes at room temperature, with a tensile load ratio (R = 0.05). These results establish relationships among fatigue limit and quasi-static mechanical properties, namely 25% × σ_r for ASA (8 MPa), 7% × σ_r for PC (3.6 MPa), 17% × σ_r for Nylon 12 (7.4 MPa), and 15% × σ_r for PC-ABS (4.7 MPa), as well as between mechanical properties and preliminary potential biomechanical applications. Main conclusions were further supported by micro-computed tomography (micro-CT), which revealed levels of porosity in between 4% and 11%, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and Fourier transform infrared spectroscopy (FTIR). Full article

Notch and size effects significantly influence the fatigue performance of engineering components, which is crucial for ensuring structural integrity. A novel probabilistic fatigue life prediction Kt-V-L model considering both the size and the notch effect, based on the theory of critical distance L (TCD) and the improved highly stressed volume V (HSV) method, is proposed in this study. The new definition more accurately characterizes fatigue damage and accumulation, overcoming the underestimation issues of traditional HSV methods under high-stress or low cycle fatigue (LCF) conditions. Specifically, the Weibull distribution is also proposed to characterize the material fatigue failure probability. The experimental data of 26Cr2Ni4MoV, En3B, and TC4 materials with varying notched sizes are utilized for the model validation and comparison. In addition, the predictive ability of the point method (Kt-V-L-PM) and line method (Kt-V-L-LM) under the novel proposed model was explored and evaluated. The predicted lives of 26Cr2Ni4MoV specimens fall within the ±2 scatter band of the Kt-V-L-LM, while the Kt-V-L-PM shows increasing deviation with larger notches due to its limited ability to capture stress gradients. For En3B and TC4, the predicted lives are within ± 2 life factors, verifying the model’s reliability and accuracy. Furthermore, fracture morphology analysis reveals the influence of notches on fatigue performance and elucidates the fracture failure mechanisms. Full article

Fatigue damage is critical for 0Cr17Ni4Cu4Nb stainless-steel components that may operate near yield under stress-controlled cycles and occasional peak holds. This work investigates the cyclic response of 0Cr17Ni4Cu4Nb stainless-steel under near-yield-stress-controlled (NYSC) loading and proposes a unified damage framework that bridges monotonic ductile fracture, near-yield stress-controlled fatigue. Building on the Enhanced Lou-Yoon model, an elastic-damage term is introduced and embedded within a continuum damage mechanics framework, allowing elastic (sub-yield) and plastic (post-yield, Ultra-Low-Cycle-Fatigue/Low-Cycle-Fatigue (ULCF/LCF)) damage to be treated in a unified, path-averaged stress-state description defined by stress triaxiality and the Lode parameter. Five stress-controlled test groups are examined, with applied load amplitudes from 20.6 to 25.1 kN (equivalent stress amplitudes 858~1044 MPa) yielding fatigue lives ranging from 32 to 13,570 cycles. The extended model captures the evolution of damage origin mechanisms from elasticity-dominated to plasticity-dominated as loading severity increases, demonstrating a unified elastic-plastic damage modeling approach. As a result, it accurately predicts fatigue lives spanning two orders of magnitude with an average absolute percentage error of approximately 14.5% across all conditions. Full article

Thousands of coastal reinforced concrete structures using HRB400 bars have served for over three decades in China. Their reinforcement simultaneously endures chloride corrosion and seismic action, yet studies on performance degradation remain limited. This paper investigates the low-cycle fatigue (LCF) behavior of HRB400 bars under various strain amplitudes, systematically analyzing corrosion morphology, cyclic stress–strain response, fatigue life, and underlying mechanisms. Corrosion is induced by an adjusted accelerated method that replicates field conditions. Observations reveal that corrosion pits act as primary crack initiation sites. Crack paths and fracture surfaces progressively follow the local pit geometry as strain and corrosion grow. The detrimental effect of corrosion on LCF life is more pronounced for smaller bars. At a γ of around 8%, 20 mm bars lose 60.7% of the half cycles to failure at ε = ±1.5%, but only 37.5% at ε = ±5.0%. Predictive corrosion-inclusive strain amplitude (ε_a)–fatigue life models are proposed, yielding R² = 0.952 (16 mm) and 0.928 (20 mm). A unified LCF predictive model, calibrated on a database of 310 corroded/uncorroded bar tests, is established. The final model comprehensively considers the characteristics of rebars, seismic action, and corrosion damage, improving the conventional relationship between LCF life and seismic loading. This work contributes to the understanding of the fatigue behavior of HRB400 bars and provides support for time-dependent seismic reliability analysis of aging reinforced concrete structures in corrosive environments. Full article

The mechanical and structural design of railway vehicles is heavily influenced by their lifetime. Because fatigue is a significant factor that impacts the longevity of railway components, it is imperative that the fatigue resistance properties of crucial components, like leaf springs, be thoroughly investigated. This research investigates the fatigue resistance of 51CrV4 steel under bending and axial tension, considering different stress ratios across low-cycle fatigue (LCF), high-cycle fatigue (HCF), and very-high-cycle fatigue (VHCF) regimes, using experimental data collected from this work and prior research. Data included fractographic analyses aiming to help in understanding some of failures for different loads. The presence of geometric discontinuities, such as notches, amplifies stress concentrations, requiring a probabilistic approach to fatigue assessment. To address notch effects, the theory of critical distances (TCD) was employed to evaluate fatigue strength. TCD model was integrated in fatigue statistical models, such as the Walker model (WSN) and the Castillo–Fernández-Cantelli model adapted for mean stress effects (ACFC). Extending the application of the TCD theory, this research provides an improved probabilistic fatigue model that integrates notch sensitivity, mean stress effects, and fatigue regimes, contributing to more reliable design approaches of railway leaf springs or other components produced in 51CrV4 steel. Full article

This study resolves the long-standing question of the origin of bilinear Low Cycle Fatigue (LCF) behavior in Ti-6Al-4V using a high-fidelity CPFEM-XFEM framework. We identify that the fundamental origin lies in a fundamental shift in the efficiency of converting macroscopic energy dissipation into microscopic damage. This energetic efficiency is directly governed by the evolution of plastic strain heterogeneity (quantified by the Coefficient of Variation, CV). At low strain amplitudes, high strain localization (high CV) creates a highly efficient “energy funnel,” concentrating dissipated energy into a few critical grains. This manifests physically as a single-crack failure mode, where the crack initiation phase is prolonged, consuming ~80% of the total fatigue life. Conversely, at high strain amplitudes, deformation homogenization (low CV) leads to inefficient, diffuse energy dissipation across many grains. The material must therefore activate a more drastic failure mechanism—multi-site crack initiation and coalescence—to accumulate sufficient damage, reducing the initiation phase to just ~45% of the total life. Therefore, the bilinear C-M curve is the macroscopic signature of this transition from an energetically efficient, localized damage mode to an inefficient, distributed one. This work provides a quantitative, mechanism-based framework for understanding and predicting the complex fatigue behavior of advanced metallic materials. Full article

Addressing the limitations of traditional fatigue life prediction methods, which rely on extensive experimental data and incur high costs, and given the current absence of studies that employ deformation inhomogeneity parameters to construct fatigue-indicator parameter (FIP) for predicting low-cycle fatigue (LCF) life of metals in hydrogen environments, this study firstly explores how hydrogen pre-charging influences the LCF behavior of hot-rolled ribbed bar grade 400 (HRB400) steel via experimental and crystal plasticity simulation, and focus on the relationship between the fatigue life and the evolution of microscale deformation inhomogeneity. The experimental results indicate that hydrogen charging causes alterations in cyclic hysteresis, an expansion of the elastic range of the stabilized hysteresis loop, and a significant reduction in LCF life. Secondly, a novel FIP was developed within the crystal plasticity finite element method (CPFEM) framework to predict the LCF life of HRB400 steel under hydrogen influence. This FIP incorporates three internal variables: hydrogen embrittlement index, axial strain variation coefficient, and macroscopic stress ratio. These variables collectively account for the hydrogen charging effects and stress peak impacts on the microscale deformation inhomogeneity. The LCF life of hydrogen-charged HRB400 steel can be predicted using this new FIP. We performed fatigue testing under only one loading condition to measure the corresponding fatigue life and determine the FIP critical value. This helped predict fatigue life under different cyclic loading conditions for the same hydrogen-charged material. We compared the experimental data to validate the novel FIP to accurately predict the LCF life of hydrogen-charged HRB400 steel. The error between the predicted results and the measured results is limited to a factor of two. Full article

Exhaust manifolds accumulate creep and fatigue damage under cyclic thermal loading, leading to localized failure. Understanding a material’s mechanical behavior is crucial for accurate life assessment. This study systematically investigated the low-cycle fatigue (LCF) and creep–fatigue interaction behaviors of medium-silicon molybdenum ductile iron. It was found that QTRSi4Mo exhibited cyclic hardening at room temperature and 400 °C, whereas it exhibited cyclic softening at 600 °C and 700 °C for low-cycle stress–strain responses. During creep–fatigue tests with hold time, variations in the strain amplitude did not alter the hysteresis loop shape or the hardening/softening characteristics of the material. They only induced a slight upward shift in the yield center. Additionally, stress relaxation primarily occurred in the initial phase of the hold period, so the hold duration had little effect on the final stress value. The investigation of creep–fatigue life models highlighted that accurately characterizing the damage induced by stress relaxation during the hold stage is critical for creep damage evaluation. The calculated creep damage results differed greatly from the experimental results of the time fraction model (TF). A combined approach using the strain energy density dissipation model (T-SEDE) and the Ostergren method demonstrated excellent predictive capability for creep–fatigue life. Full article

The fatigue life curve was determined for the AL6XN stainless steel under strain-controlled Low Cycle Fatigue (LCF) tests. Additionally, a specific number of loading cycles were applied to new specimens made from the same AL6XN alloy batch to set an Accumulated Fatigue Damage (AFD) based on the Palmgren–Miner rule. The AFD was 0.25, 0.50 and 0.75; subsequently, these specimens were subjected to tensile tests. It was observed that all AFD specimens exhibited a yield strength increment with respect to the AL6XN material property, thus, it was similar to a strain-hardening mechanism. However, the stress–strain behavior and microstructure characterization showed a microvoid nucleation and growth mechanism that competed against the strain-hardening one. The fracture in the 0.75 AFD specimens was dominated by this microvoid-based mechanism. The experimental results indicated that the strain-hardening exponent (n-value) and electrical resistivity ($\rho$-value) were consistently modified by the AFD in all the specimens, with an inverse linear relationship for the n-value and a nonlinear increasing behavior for the $\rho$-value. Full article

The longevity of railway vehicles is an important factor in their mechanical and structural design. Fatigue is a major issue that affects the durability of railway components, and, therefore, knowledge of the fatigue resistance characteristics of critical components, such as leaf springs, must be extensively investigated. This research covers the fatigue resistance of 51CrV4 steel under bending and axial tension, for distinct stress ratios, in the low-cycle fatigue regime (LCF), high-cycle fatigue regime (HCF), and very high-cycle fatigue regime (VHCF) using experimental data collected in this work and from previous experiments. Two fatigue models were analyzed: the Walker model (WSN) and the Castillo–Fernández–Cantelli model, CFC, adapted for the presence of mean stress (ACFC). According to the analysis carried out, both fatigue resistance prediction models provided good results for the experimental data, with the ACFC model showing good fitting when considering all the failure data and outliers. Additionally, fracture surfaces showed a higher trend for crack initiation on the surface for positive stress ratios despite internal defects also possibly being responsible for some fatigue failures. This investigation aimed to provide a probabilistic fatigue model encompassing the LCF, HCF, and VHCF fatigue regimes for distinct stress ratios for the fatigue design analysis of 51CrV4 steel parabolic leaf springs manufactured by hot-forming processes with subsequent heat treatments. Full article

The VITAL-E (Versatile Innovative Testing Low-Cycle Fatigue for Elastomers) project introduces a shift in low-cycle fatigue (LCF) testing by replacing traditional hydraulic systems with an electromechanical solution. Hydraulic machines, although widely used, present issues such as fluid leakage, environmental impact, high maintenance, and complex feedback control. In contrast, VITAL-E incorporates a zero-backlash linear actuator, addressing a key challenge in electromechanical systems: backlash. This issue, caused by axial movement between the nut and screw during load reversals, can disrupt load application and compromise test accuracy. By eliminating backlash, the chosen actuator ensures continuous and precise load application, especially during critical cycle reversals, enhancing both the accuracy and reliability of LCF testing. Beyond technical improvements, the electromechanical system reduces component complexity, wear, and maintenance needs while offering easier upgrades and adaptability to evolving testing demands. Compared to conventional hydraulic systems, VITAL-E’s design offers an innovative industrial solution, promoting a new generation of LCF test machines that excel in accuracy, reliability, and operational efficiency. This innovation aligns with the growing demand for sustainable and adaptable testing solutions, particularly in the automotive industry, ensuring that LCF testing remains relevant for future research and industrial needs. Full article

Resistance spot welding (RSW) is now the primary joining process used in the automobile and aerospace sectors. Mechanical parts, when put into service, often undergo cyclic stress. As a result, avoiding fatigue failure should be the top priority when designing these parts. Given that spot welds are a type of localised joining that results in intrinsic circumferential notches, they increase the likelihood of stress concentrations and subsequent fatigue failures of the structure. Most of the fatigue failures in automotive parts originate around a spot weld. To that end, this study seeks to examine the mechanical properties and fatigue behaviour RSW joints made of titanium (Ti) grade 2 alloy and AISI 304 austenitic stainless steel (ASS) with equal and unequal thicknesses of 0.5 and 1 mm. Based on the mechanical properties and fatigue life results, the maximum tensile shear strength and fatigue life for the RSW titanium joint were 613 MPa and 7.37 × 10⁵ cycles for the 0.5–0.5 mm case, 374.7 MPa and 1.39 × 10⁶ cycles for the 1–1 mm case, and 333.5 MPa and 7.69 × 10⁵ cycles for the 1–0.5 mm case, respectively. The maximum shear strength and fatigue life of ASS welded joints were 526.8 MPa and 4.56 × 10⁶ cycles for the 1–1 mm case, 515.2 MPa and 3.35 × 10⁶ cycles for the 0.5–0.5 mm case, and 369.5 MPa and 7.39 × 10⁵ cycles for the 1–0.5 mm case, respectively. The assessment of the shear strength and fatigue life of the dissimilar joints revealed that the maximum shear strength and fatigue life recorded were 183.9 MPa and 6.47 × 10⁵ cycles for the 1 mm Ti–0.5 mm ASS case, 115 MPa and 3.7 × 10⁵ cycles for the 1 mm Ti–1 mm ASS case, 156 MPa and 4.11 × 10⁵ cycles for the 0.5 mm Ti–0.5 mm ASS case, and 129 MPa and 4.11 × 10⁵ cycles for the 0.5 mm Ti–1 mm ASS case. The fatigue life of titanium and stainless steel welded joints is significantly affected by the thickness, particularly at maximum applied stress (0.9% UTS), meaning that similar thicknesses achieve a greater fatigue life than unequal thicknesses. Conversely, the fatigue life of the dissimilar joint reached the greatest extent when an unequal thickness combination was used. The ductile failure of similar Ti and ASS welded joints was demonstrated by the scanning electron microscopy (SEM) examination of fatigue-fractured surfaces under the high-cycle fatigue (HCF) regime, in contrast to the brittle failure noticed in the low-cycle fatigue (LCF) regime. Brittle failure was confirmed by the SEM fatigue of dissimilar joint fractured surfaces due to interfacial failure. The Ti and ASS fractured surfaces presented river-like cleavage facets. On the Ti side, tiny elongated dimples suggest ductile failure before fracture. The topography results showed that the roughness topography parameters of similar and dissimilar fractured specimens made from Ti grade 2 and AISI 304 for the HCF regime were lower than those of the fractured specimens with LCF. The current study is expected to have practical benefits for the aerospace and automotive industries, particularly the manufacturing of body components with an improved strength-to-weight ratio. Full article

A novel method is proposed for a combined high and low cycle fatigue (CCF) life prediction model based on Miner’s rule, incorporating load interactions and coupled damage effects to evaluate the fatigue life of wind turbine blades under CCF loading. The method refines the CCF damage curve by modeling the complex damage evolution process under L-H loading and establishes a life prediction model linking low cycle fatigue (LCF) and high cycle fatigue (HCF) damage curves for more accurate predictions. Compared to Miner’s rule, the M-H model, and the T-K model, the proposed approach demonstrates superior prediction accuracy, with results predominantly falling within a life factor of ±1.5. To verify the model’s practical applicability, finite element analysis (FEA) was performed on critical blade sections, reducing the prediction error to 4.3%. This method introduces a novel approach for evaluating the fatigue life of wind turbine blades with improved accuracy over existing methods. Full article

Single crystal nickel-based superalloys are extensively used in turbine blade applications due to their superior creep resistance compared to their polycrystalline counterparts. With the high creep resistance, high cycle fatigue (HCF) and low cycle fatigue (LCF) become primary failure mechanisms for such applications. This study investigates the fatigue life prediction of CMSX-4 using a combination of crystal plasticity and lifetime assessment models. The constitutive crystal plasticity model simulates the anisotropic, rate-dependent deformation behavior of CMSX-4, while the modified Chaboche damage model is used for lifetime assessment, focusing on cleavage stresses on active slip planes to include anisotropy. Both qualitative and quantitative data obtained from HCF experiments on single crystal superalloys with notched geometry were used for validation of the model. Furthermore, artificial neural networks (ANNs) were employed to enhance the accuracy of lifetime predictions across varying temperatures by analyzing the fatigue curves obtained from the damage model. The integration of crystal plasticity, damage mechanics, and ANNs resulted in an accurate prediction of fatigue life and crack initiation points under complex loading conditions of single crystals superalloys. Full article