Comparison of methods for the determination of fatigue critical flaw size and implementation for probabilistic fatigue assessment

IF 6.8 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-09-06 DOI:10.1016/j.ijfatigue.2025.109252

Lorenzo Rusnati , Giuliano Minerva , Luca Patriarca , Stefano Miccoli , Stefano Beretta

{"title":"Comparison of methods for the determination of fatigue critical flaw size and implementation for probabilistic fatigue assessment","authors":"Lorenzo Rusnati , Giuliano Minerva , Luca Patriarca , Stefano Miccoli , Stefano Beretta","doi":"10.1016/j.ijfatigue.2025.109252","DOIUrl":null,"url":null,"abstract":"<div><div>The correct evaluation of the impact of defects in the structural integrity of metal additively manufactured components is a necessary step to be addressed for the broader adoption of the additive manufacturing technology. The effect of flaws on fatigue strength of materials can be evaluated through different theoretical approaches, among which fracture mechanics-based theory was successfully applied in several applications. However, each method presents notable differences which alter the life estimates of parts. Therefore, in this work, the authors compare the fatigue life predicted by four different methods against results from a wide fatigue test campaign on Ti-6Al-4V specimens in different conditions. Then, critical defect size curves, identifying the stress–defect–life relation from each of the analysed model, are established and critically evaluated. Finally, the fatigue strength model based on explicit crack growth analysis, which is the standard assessment method for fracture control, is implemented in ProFACE software. This allows to determine the critical initial flaw size in probabilistic fatigue analyses of components, addressing different geometries and materials.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"203 ","pages":"Article 109252"},"PeriodicalIF":6.8000,"publicationDate":"2025-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"International Journal of Fatigue","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0142112325004499","RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MECHANICAL","Score":null,"Total":0}

引用次数: 0

Abstract

The correct evaluation of the impact of defects in the structural integrity of metal additively manufactured components is a necessary step to be addressed for the broader adoption of the additive manufacturing technology. The effect of flaws on fatigue strength of materials can be evaluated through different theoretical approaches, among which fracture mechanics-based theory was successfully applied in several applications. However, each method presents notable differences which alter the life estimates of parts. Therefore, in this work, the authors compare the fatigue life predicted by four different methods against results from a wide fatigue test campaign on Ti-6Al-4V specimens in different conditions. Then, critical defect size curves, identifying the stress–defect–life relation from each of the analysed model, are established and critically evaluated. Finally, the fatigue strength model based on explicit crack growth analysis, which is the standard assessment method for fracture control, is implemented in ProFACE software. This allows to determine the critical initial flaw size in probabilistic fatigue analyses of components, addressing different geometries and materials.

Abstract Image

查看原文本刊更多论文

疲劳临界裂纹尺寸确定方法的比较及概率疲劳评估的实现

正确评估金属增材制造部件结构完整性缺陷的影响是增材制造技术广泛应用的必要步骤。裂纹对材料疲劳强度的影响可以通过不同的理论方法来评估，其中基于断裂力学的理论已成功应用于多个应用中。然而，每种方法都存在显著差异，从而改变了零件的寿命估计。因此，在这项工作中，作者将四种不同方法预测的疲劳寿命与不同条件下Ti-6Al-4V试样的广泛疲劳试验结果进行了比较。然后，建立临界缺陷尺寸曲线，从每个分析模型中识别应力-缺陷-寿命关系，并对其进行严格评估。最后，在ProFACE软件中实现了基于显式裂纹扩展分析的疲劳强度模型，该模型是断裂控制的标准评估方法。这允许确定组件的概率疲劳分析的临界初始缺陷尺寸，处理不同的几何形状和材料。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.