{"title":"A New Nonlinear Fatigue Cumulative Damage Model Based on Enhanced Whale Optimization Algorithm and Manson–Halford Model","authors":"Yuhan Tang, Yuedong Wang, Qi Dong, Yonghua Li, Tao Guo, Zhiyang Zhang","doi":"10.1111/ffe.14689","DOIUrl":"https://doi.org/10.1111/ffe.14689","url":null,"abstract":"<div>\u0000 \u0000 <p>In the field of modern mechanical engineering, structures often endure multi-level variable stress loading. The nonlinear fatigue cumulative damage process of these structures is highly complex due to the significant influence of loading sequences and interactions, which makes fatigue life prediction difficult. To accurately describe the impacts of these factors on fatigue damage, this paper proposes a nonlinear fatigue cumulative damage model (EWOA-MH) based on the enhanced whale optimization algorithm (EWOA) and the Manson–Halford (M-H) model. This model obtains weight factors through EWOA and incorporates them into the M-H model. Verified by experimental data of multi-level variable stress loading and calculated with a weighted method considering different materials' sample numbers, the prediction accuracy is increased by approximately 43%. Its application to the analysis of high-speed train bogie frames effectively demonstrates the model's effectiveness. The research shows that the EWOA-MH model performs outstandingly in fatigue life prediction and can effectively solve fatigue damage problems under multi-level variable stress loading conditions.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3528-3544"},"PeriodicalIF":3.1,"publicationDate":"2025-05-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598781","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shijie Li, Chuanzhen Huang, Hanlian Liu, Zhenyu Shi, Lianggang Ji, Xinyao Cui, Chongzhen Du, Zhen Wang, Longhua Xu, Shuiquan Huang
{"title":"Fracture Toughness Modeling and Toughening Mechanisms Taking Into Account Grain Growth and Crack Deflections of Bionic Ceramic Cutting Tool Materials","authors":"Shijie Li, Chuanzhen Huang, Hanlian Liu, Zhenyu Shi, Lianggang Ji, Xinyao Cui, Chongzhen Du, Zhen Wang, Longhua Xu, Shuiquan Huang","doi":"10.1111/ffe.14693","DOIUrl":"https://doi.org/10.1111/ffe.14693","url":null,"abstract":"<div>\u0000 \u0000 <p>A theoretical model of fracture toughness for bionic ceramic cutting tools was established by bionic design of the macro and micro toughening mechanisms of shells. This model can guide and optimize the fabrication process based on the required fracture toughness. Then, by prefabricating the macro-strong physical bonding interface, the effect laws of compositions and structural parameters on the theoretical model of fracture toughness and the toughening mechanism are obtained. The results show that the interface strengthening effect is gradually enhanced with the decrease of layer thickness ratio and the increase of the number of layers. The synergistic effects of multiple crack deflections, interfacial strengthening mechanisms (residual stress toughening and stepped fracture) and nanoparticle toughening improve the mechanical properties of bionic ceramic cutting tools. This theoretical model offers an advanced design concept and functional application for laminated materials.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3545-3562"},"PeriodicalIF":3.1,"publicationDate":"2025-05-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598782","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Faezeh Javadzadeh Kalahroudi, Dimitrios Nikas, Tomas Berglund, Mikael Grehk
{"title":"Effect of Stress Ratio on Very High Cycle Fatigue Properties of PM-HIPed Inconel 625","authors":"Faezeh Javadzadeh Kalahroudi, Dimitrios Nikas, Tomas Berglund, Mikael Grehk","doi":"10.1111/ffe.14683","DOIUrl":"https://doi.org/10.1111/ffe.14683","url":null,"abstract":"<p>This study investigated the impact of stress ratio on the fatigue performance and fatigue crack initiation characteristics of PM-HIPed Inconel 625 in the very high cycle regimes. Ultrasonic fatigue tests, operating at a frequency of 20 kHz, were conducted on PM-HIPed Inconel 625 samples under stress ratios of <i>R</i> = −1 and 0.1 up to the ultimate fatigue life of 10<sup>9</sup> cycles. Detailed fractographic and microstructural analyses were conducted to identify the mechanisms of crack initiation. The results revealed that stress ratio played a critical role in the crack initiation process. At <i>R</i> = 0.1, cracks predominantly initiated at carbonitrides and non-metallic inclusions, with neighboring crystallographic facets assisting in the formation of microcracks. Conversely, at <i>R</i> = −1, crack initiation was driven by large gains and triple junctions. Microstructural characteristics resulting from the HIP process significantly influenced fatigue crack initiation. Prior particle boundaries were found to affect fatigue crack initiation behavior through the presence of large grains within the boundaries, as well as carbonitrides and non-metallic inclusions networks along the rim. The discussion explored fracture mechanics, fracture surface analyses, and associated microstructural properties to elucidate the observed phenomenon.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3593-3610"},"PeriodicalIF":3.1,"publicationDate":"2025-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1111/ffe.14683","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598336","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Y. G. Wang, L. L. Wei, Z. J. Tan, S. X. Wang, J. Y. Yang, L. F. Yang, J. Chen
{"title":"Fatigue Behavior and Fracture Mechanism of 310S Austenitic Stainless Steel Processed by Surface Mechanical Rolling Treatment at 650°C","authors":"Y. G. Wang, L. L. Wei, Z. J. Tan, S. X. Wang, J. Y. Yang, L. F. Yang, J. Chen","doi":"10.1111/ffe.14685","DOIUrl":"https://doi.org/10.1111/ffe.14685","url":null,"abstract":"<div>\u0000 \u0000 <p>This study investigates the microstructure, residual stress stability, fatigue property, and fracture mechanism of a gradient structure specimen fabricated on 310S austenitic stainless steel via surface mechanical rolling treatment at 650°C. The gradient structure enhances yield strength and ultimate tensile strength by 100% and 12.4%, respectively. Fatigue strength improves across a wide strain amplitude range due to the gradient microstructure and multiaxial stress state. Fatigue ductility increases when Δ<i>ε</i>/2 < 0.45% but decreases at higher strains. Compressive residual stress has minimal impact on fatigue properties due to rapid relaxation at 650°C. Fractography analysis reveals grain coarsening and sigma brittle phase precipitation after high-temperature fatigue. All fatigue cracks initiate in the oxide layer, driven by high stress concentrations at grain boundaries, leading to brittle intergranular and interfacial cracking. These findings highlight the role of the gradient structure in improving mechanical performance under elevated temperatures.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3501-3516"},"PeriodicalIF":3.1,"publicationDate":"2025-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598338","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yan Gao, Yanquan Zhou, Zequn Lin, Chenxing Gong, Zihan Ling
{"title":"Size Effects and Hygrothermal Aging on Mode II Interlaminar Fracture Toughness of Thick CFRP Composites","authors":"Yan Gao, Yanquan Zhou, Zequn Lin, Chenxing Gong, Zihan Ling","doi":"10.1111/ffe.14690","DOIUrl":"https://doi.org/10.1111/ffe.14690","url":null,"abstract":"<div>\u0000 \u0000 <p>The size effects and hygrothermal aging behavior of Mode II interlaminar fracture toughness (<i>G</i><sub>II<i>c</i></sub>) for thick composites are investigated. Experimental results demonstrate that increasing specimen thickness leads to a rise in <i>G</i><sub>II<i>c</i></sub> for NPC and PC tests from 0.99 and 0.64 kJ/m<sup>2</sup> to 1.41 and 0.97 kJ/m<sup>2</sup>, respectively. FE simulation results indicate that the increase in the fracture process zone (FPZ) area plays a crucial role in contributing to the size effects observed in <i>G</i><sub>II<i>c</i></sub>. The ENF specimens exhibit a significant decrease in glass transition temperature (<i>T</i><sub><i>g</i></sub>) along with noticeable changes in fracture morphology. The <i>G</i><sub>II<i>c</i></sub> values obtained from NPC tests are significantly lower than those of unaged specimens. However, hygrothermal aging has no effect on the crack propagation behavior and <i>G</i><sub>II<i>c</i></sub> values in PC tests. These findings provide practical insights for designing and predicting the service life of composite components exposed to humid and high-temperature environments.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3517-3527"},"PeriodicalIF":3.1,"publicationDate":"2025-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598339","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"A Novel Method for Estimating Fatigue Properties of Plain Weave Composites Under Nonstationary Random Loads Based on Residual Strength","authors":"Chaozhi Yang, Yi Sun, Yizhi Liu, Shuai Ma, Yongbin Dang, Zhengxuan Guan","doi":"10.1111/ffe.14684","DOIUrl":"https://doi.org/10.1111/ffe.14684","url":null,"abstract":"<div>\u0000 \u0000 <p>In practical fatigue scenarios, certain fatigue processes exhibit nonstationary characteristics rather than stationary ones. This paper presents a novel approach for estimating fatigue properties of composite materials under nonstationary stochastic loads, leveraging a fusion of time-domain and frequency-domain analyses to capitalize on their respective strengths. By introducing the evolutionary power spectrum, the residual strength combining frequency-domain analysis method extends its application from stationary random processes to nonstationary ones. This method derives the integral equation of residual strength under nonstationary random loads and solves it using a differential method. This method requires only the S-N curve under a specific stress ratio and the corresponding residual strength degradation law for life prediction. To improve the generality of the model, fatigue tests at multiple stress ratios were conducted in this study to construct a constant life diagram (CLD), from which S-N curve parameters at arbitrary stress ratios can be interpolated. This approach not only reduces computational complexity but also yields reliable results. Furthermore, it considers both the randomness of the load and the dispersion of the composite material, allowing for the prediction of failure probability under nonstationary random conditions. Fatigue tests under two types of nonstationary random loads were obtained. The prediction results are basically within 1.5 times the error range.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3487-3500"},"PeriodicalIF":3.1,"publicationDate":"2025-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598337","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zhonghua Jiang, Jingyu Sun, Filippo Berto, Xi Wang, Guian Qian
{"title":"Fatigue Behavior and Life Prediction of Additively Manufactured AlSi10Mg up to 108 Cycles Under Rotating Bending","authors":"Zhonghua Jiang, Jingyu Sun, Filippo Berto, Xi Wang, Guian Qian","doi":"10.1111/ffe.14673","DOIUrl":"https://doi.org/10.1111/ffe.14673","url":null,"abstract":"<div>\u0000 \u0000 <p>Laser powder bed fusion (L-PBF) technology has been commonly used in various industries to manufacture small-lot or complex parts. However, process-induced defects are inevitable, which limits the adoption of L-PBF alloys for load-bearing components. This work studied the fatigue behavior of L-PBF AlSi10Mg subjected to rotating bending loading up to 10<sup>8</sup> cycles, and compared two batches of specimens with different layer thicknesses of 50 and 80 μm. The results indicate that the specimens with a layer thickness of 50 μm exhibit better fatigue strength compared to those with a layer thickness of 80 μm. Fracture analysis shows that lack of fusion defects are the crack initiation location, and the characteristics of these defects have a significant effect on the fatigue behavior. Furthermore, the Kitagawa–Takahashi diagram was used to determine the safe life region in terms of the El-Haddad formula. Finally, by taking into account the size, location, and shape of the defects, a modified model was proposed to predict the fatigue life. The predicted results are in good agreement with the experimental results.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3580-3592"},"PeriodicalIF":3.1,"publicationDate":"2025-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598335","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
He-Fei Li, Wen-Zhe Zhang, Shao-Pu Yang, Guo-Jie Cai, Xiao-Di Wang
{"title":"Study on the High-Cycle Fatigue and Fatigue Crack Growth Behavior of Al–Si–Mg Alloy: Pore Size and Stress Ratio Effects","authors":"He-Fei Li, Wen-Zhe Zhang, Shao-Pu Yang, Guo-Jie Cai, Xiao-Di Wang","doi":"10.1111/ffe.14688","DOIUrl":"https://doi.org/10.1111/ffe.14688","url":null,"abstract":"<div>\u0000 \u0000 <p>Defects are inevitable products during the manufacturing process of cast aluminum alloys, which have a significant impact on the service performance of engineering components under complex loadings. However, the effects of casting defects and stress ratio on the fatigue properties of Al–Si–Mg alloys are still not fully understood. In this study, the effects of pores defects and stress ratio on high-cycle fatigue and fatigue crack growth behavior of Al–Si–Mg alloy were systematically investigated. The experimental results show that the high-cycle fatigue properties of Al–Si–Mg alloy exhibit high dispersion, while low dispersion displayed for the fatigue crack growth rate. Based on the mechanical parameters and fracture characteristics, it is elucidated that the pore defect has a greater effect on crack initiation than crack growth mechanism in Al–Si–Mg alloy. According to the data validation, Goodman's model could well explain the stress ratio effect on the fatigue strength of Al–Si–Mg alloy than Walker's and SWT's models. Additionally, Kujawski's model, Huang's model, Zhan's model, and Li's model all could predict the fatigue crack growth rate of Al–Si–Mg alloy for different stress ratios. There is no material-dependent parameter in Li's model, which might be an advantage in predicting fatigue crack growth rate of metallic materials.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3475-3486"},"PeriodicalIF":3.1,"publicationDate":"2025-05-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598345","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
E. V. Naydenkin, I. P. Mishin, V. A. Oborin, A. I. Manisheva
{"title":"The Alpha-Case Formation Effect on Very High Cycle Fatigue and Fracture of Ultrafine-Grained Near β Titanium Alloy","authors":"E. V. Naydenkin, I. P. Mishin, V. A. Oborin, A. I. Manisheva","doi":"10.1111/ffe.14681","DOIUrl":"https://doi.org/10.1111/ffe.14681","url":null,"abstract":"<div>\u0000 \u0000 <p>Ultrasonic testing was conducted to investigate for the first time the impact of alpha-case formation during air aging (450°C, 5 h) on the very high cycle fatigue (VHCF) and failure of an ultrafine-grained (UFG) near β Ti-5Al-5V-5Mo-1Cr-1Fe alloy. The research findings indicate that air aging results in the development of an alpha-case layer, diminishing the fatigue properties of the UFG titanium alloy produced by radial shear rolling during VHCF testing. The fatigue limit of the alloy samples with an oxide layer decreased from approximately 620 to 520 MPa based on 10<sup>9</sup> cycles. Examination of the fatigue failure mechanisms revealed that the alpha-case layer does not significantly impact crack initiation at stress amplitudes below 650 MPa but does accelerate crack propagation. In the alloy without an oxide layer, at all stress amplitudes, the crack initiation is internal. Oxidation leads to a change in the crack initiation mechanism from internal to subsurface at stress amplitudes above 650 MPa with low-cycle fatigue failure.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3465-3474"},"PeriodicalIF":3.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598323","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zifan Hu, Zhiqiang Zhang, Cheng Li, Rui Sun, Ibrahim Elbugdady, Wei Li
{"title":"Microscale Investigation on the Monotonic Tension and Fatigue Deformation-Failure Mechanisms of TiC/Ti6Al4V Composites","authors":"Zifan Hu, Zhiqiang Zhang, Cheng Li, Rui Sun, Ibrahim Elbugdady, Wei Li","doi":"10.1111/ffe.14679","DOIUrl":"https://doi.org/10.1111/ffe.14679","url":null,"abstract":"<div>\u0000 \u0000 <p>The microstructure where compositions interact with each other dominates the macroscopic properties of composites, but microscale deformation-failure mechanisms especially under fatigue remain unclear. Herein, the deformation-failure mechanisms of TiC/Ti6Al4V composites with three reinforcement volume fractions are investigated. Under monotonic tension, increased reinforcement content enhances yield strength and Young's modulus but reduces tensile strength due to reinforcement failure in the later stage, leaving the matrix as the primary load-bearing component. Dislocation density increases continuously and monotonously, dominated by Shockley dislocations, with subsequent length reduction attributed to the Orowan mechanism. Under cyclic tensile loading, composites with higher reinforcement content gradually exhibit cyclic hardening, while they show cyclic softening under cyclic compression even in early cycles due to back stress effect. Dislocation sources cause uneven distribution and repeated multiplication of dislocations. Localized atomic stress concentration promotes phase transitions, altering the microstructure and driving crack initiation and propagation.</p>\u0000 </div>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"48 8","pages":"3416-3433"},"PeriodicalIF":3.1,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144598324","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}