{"title":"Predicting fatigue failure in five-axis machined ball-end milled components through FKM local stress approach","authors":"Zayeem Fazili, Simon Barrans, Karl Walton","doi":"10.1111/ffe.14403","DOIUrl":"https://doi.org/10.1111/ffe.14403","url":null,"abstract":"<p>Components created with five-axis machining show a multi-scale surface character due to cusps created on the surface and feed and tool marks within the cusps. Therefore, it becomes difficult to incorporate the effects of surface character on fatigue life for such components. In this work, an Forschungskuratorium Maschinenbau (FKM) guideline is adapted to develop a fatigue prediction model which considers cusps as notches and marks within the cusps as surface roughness (characterized by parameter R10z). The assessment uses stresses obtained from an finite element analysis model to predict the fatigue life of components whilst considering stress concentration, stress gradient, mean stress, and surface roughness effects. When cusps are regarded as surface roughness within the conventional FKM approach, fatigue life is considerably underestimated. In comparison, fatigue life predictions that take into consideration the roughness within cusps and treat cusps as stress-raising notches are closer to experimental life.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3773-3790"},"PeriodicalIF":3.1,"publicationDate":"2024-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1111/ffe.14403","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158641","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}
{"title":"Entropy-based method considering nonlinear hardening effect to predict the crack propagation life of superalloy GH4169 at elevated temperature","authors":"Shuiting Ding, Liangliang Zuo, Guo Li, Zhenlei Li, Huimin Zhou, Shaochen Bao, Shuyang Xia","doi":"10.1111/ffe.14391","DOIUrl":"https://doi.org/10.1111/ffe.14391","url":null,"abstract":"<p>This paper aims to determine the relationship between thermodynamic entropy generation and fatigue crack propagation life of superalloy GH4169 at 300–650°C. The entire specimen was considered as the thermodynamic system. The plastic energy dissipation in the crack tip was obtained by finite element simulation utilizing the Chaboche nonlinear hardening model. Then the cyclic entropy generation rate (CEGR) and the accumulated entropy generation are calculated by combining simulation and experimental methods. Results show that the CEGR is a power function of the stress intensity factor range, and it is almost a constant at fatigue failure. The fatigue fracture entropy (FFE) increases as fatigue cycles at failure increase at constant temperature, but it first decreases and then increases when temperature increases from 300 to 650°C. A fatigue life prediction model based on the thermodynamic damage parameter is established and verified by comparison with experimental results and available data in the literature.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3739-3756"},"PeriodicalIF":3.1,"publicationDate":"2024-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158509","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}
Nesar Merah, Jafar Albinmousa, Muhammed J. Adinoyi, Usman Ali
{"title":"Multiaxial fatigue behavior and life estimation of Al-Li alloy 2099 under strain-controlled loading","authors":"Nesar Merah, Jafar Albinmousa, Muhammed J. Adinoyi, Usman Ali","doi":"10.1111/ffe.14408","DOIUrl":"https://doi.org/10.1111/ffe.14408","url":null,"abstract":"<p>Aluminum-lithium alloys are a class of advanced materials designed to reduce weight and improve performance in aerospace and other high-tech applications. This paper presents a research investigation on the in-phase and out-of-phase multiaxial fatigue behaviors of the third-generation AW2099-T83 aluminum-lithium alloy that have not been addressed before. Additional hardening was observed under nonproportional loading condition at high strain amplitudes. Fatigue lives were estimated using von Mises equivalent strain and two critical plane models: the Fatemi-Socie (FS) and the Smith-Watson-Topper (SWT). In addition, a supervised machine-learning model (support vector machine—SVM) was employed to predict the fatigue life under the above-mentioned loading conditions. The FS criterion was found to yield better fatigue life predictions than SWT. The estimations of FS model mostly fall within ±3× scatter bands with some data falling within the conservative and non-conservative regions. The SVM model resulted in excellent predictions within ±2× scatter bands.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3757-3772"},"PeriodicalIF":3.1,"publicationDate":"2024-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158560","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 one-dimensional phenomenological constitutive model of shape memory alloys considering the cyclic degradation of two-way memory effect","authors":"Jiacheng Zhang, Yongxi He, Jiang Zhu, Ruixiang Zhang, Yiqun Zhang","doi":"10.1111/ffe.14399","DOIUrl":"https://doi.org/10.1111/ffe.14399","url":null,"abstract":"<p>This study introduces a one-dimensional phenomenological constitutive model designed to describe two-way shape memory effect (TWSME) and its associated cyclic degradation. The model utilizes the logistic function to formulate the phase transformation equation, incorporates the expansion of key parameters into their respective fatigue functions to characterize the fatigue phenomenon, and integrates a phase transformation rate regulation function into the differential form of the phase transformation equation. This integration facilitates the control over the entire phase transformation process and the simulation of incomplete transformations. The model is distinguished by its comprehensive functionality, simple form, ease of calculation, and the clear and direct influence of key parameters. Furthermore, it offers a degree of flexibility because each function within the framework is replaceable. The simulation of the TWSME strain and recovery stress hysteresis loop deformation has been successfully conducted, enabling the description of internal hysteresis loops caused by incomplete transformation. The validity of the model is corroborated by comparing it with existing experimental results.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3723-3738"},"PeriodicalIF":3.1,"publicationDate":"2024-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158508","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":"Impact of a single-side 100Cr6 clad layer on the tensile and fatigue properties of S550MC steel","authors":"M. Krochmal, T. Wegener, T. Niendorf","doi":"10.1111/ffe.14383","DOIUrl":"https://doi.org/10.1111/ffe.14383","url":null,"abstract":"<p>The production of newly developed hot-rolled layered metal composites (LMC) leads to the availability of sheet materials with specifically adjustable, graded properties being cost-effective and suitable for large-scale production. As many of the envisaged applications of these LMC, e.g., clutch disc carriers, suffer from cyclic loading during service life, a fundamental knowledge of the fatigue behavior is required in order to ensure safe and reliable application of the components. Therefore, the present study focuses on the fatigue behavior of a hot-rolled two-layer LMC consisting of a S550MC substrate layer and a 100Cr6 clad layer. In order to investigate the influence of the clad layer, two conditions are directly compared, i.e., the two-layer laminate cladded steel and the single-layer substrate condition. Results presented by mechanical testing include hardness measurements and tensile tests as well as strain-controlled low-cycle fatigue and stress-controlled high-cycle fatigue tests. These results are discussed based on evolution of microstructure, residual stress, and defects, respectively, as elaborated by scanning electron microscopy, X-ray diffraction, and fracture surface analysis.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3707-3722"},"PeriodicalIF":3.1,"publicationDate":"2024-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1111/ffe.14383","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158590","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}
{"title":"The fatigue responses of 3D-printed polylactic acid (PLA) parts with varying raster angles and printing speeds","authors":"Murat Horasan, Ismail Sarac","doi":"10.1111/ffe.14406","DOIUrl":"https://doi.org/10.1111/ffe.14406","url":null,"abstract":"<p>In this study, the fatigue behavior of FDM-3D printed polylactic acid (PLA) materials was investigated by rotary bending fatigue tests and finite element studies with varying printing speed and raster angle parameters. Fatigue test specimens were manufactured at five different raster angles (0°, 30°, 45°, 60°, and 90°) and two different printing speeds (20 and 80 mm/s). The effect of printing speed was evaluated at high print speed variation range (20 and 80 mm/s print speeds). It was noticed that the change in raster angle affects the fatigue life very significantly. The highest fatigue life was obtained at 30° raster angle, while the lowest fatigue life was found at 90° raster angle. Increasing the printing speed from 20 to 80 mm/s decreased the fatigue life of all specimens. The derived results from the finite element analyses were consistent with the experimental results.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3693-3706"},"PeriodicalIF":3.1,"publicationDate":"2024-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1111/ffe.14406","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158589","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}
Abedulgader Baktheer, Soheil Esfandiari, Mario Aguilar, Henrik Becks, Martin Classen, Rostislav Chudoba
{"title":"Fatigue-induced stress redistribution in prestressed concrete beams modeled using the constitutive hypothesis of inter-aggregate degradation","authors":"Abedulgader Baktheer, Soheil Esfandiari, Mario Aguilar, Henrik Becks, Martin Classen, Rostislav Chudoba","doi":"10.1111/ffe.14388","DOIUrl":"https://doi.org/10.1111/ffe.14388","url":null,"abstract":"<p>Despite of intensive research on concrete fatigue, the transfer of fatigue characteristics determined at the material level to the structural level remains a challenging issue. In this paper, the propagation of fatigue-induced damage through the concrete structure is analyzed using a microplane fatigue model for concrete recently developed by the authors. To this end, our recent experimental study in which the fatigue propagation was monitored at the structural level represented by prestressed concrete beams is used to derive a general interpretation of the stress redistribution process using of the developed model. The numerical studies show that the developed microplane fatigue model provides a powerful computational tool for in-depth analysis of the correspondence between the fatigue behavior at the material and structural scales in a wide range of load configurations. In addition, the thermodynamically based constitutive model allows for the quantification of the energy dissipation during the process, revealing the possibility of deriving material-specific energetic characteristics that can further help to make the predictions of fatigue life more accurate.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3673-3692"},"PeriodicalIF":3.1,"publicationDate":"2024-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1111/ffe.14388","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158675","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}
{"title":"Fracture behavior analysis and fatigue assessment of the spring clip in heavy-haul railway","authors":"Yu-Xuan Wang, Wen-Jun Xiao, Zhi-Feng Wang, Yong Liu, Er-Bo Wang, Hong-Tao Chang","doi":"10.1111/ffe.14401","DOIUrl":"https://doi.org/10.1111/ffe.14401","url":null,"abstract":"<p>This paper proposes a novel method based on a numerical simulation approach and fatigue fracture theory to analyze the fracture behavior and assess the fatigue life of spring clips. To this end, the finite element (FE) model of the vehicle-track-foundation system was developed including the key parts of the type II fastening system. Meanwhile, the spring clip FE model was validated through the natural vibration characteristics. Subsequently, the numerical simulations were performed under various working conditions to obtain the fatigue characteristics of the spring clips. The fatigue crack initiation life and damage were analyzed using FE results for the spring clips with <i>ε-N</i> curve and Brown-Miller criterion. Moreover, based on the initial crack geometry of the spring clips, the maximum circumferential stress criterion with the Paris equation was employed to analyze the crack extension behavior and assess the fatigue crack extension life.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3658-3672"},"PeriodicalIF":3.1,"publicationDate":"2024-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158673","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}
Le Xu, Lv-Yi Cheng, Kai-Shang Li, Ken Suzuki, Hideo Miura, Run-Zi Wang
{"title":"Creep damage evolution by cavity nucleation and growth considering the cavity closure under cyclic loading conditions","authors":"Le Xu, Lv-Yi Cheng, Kai-Shang Li, Ken Suzuki, Hideo Miura, Run-Zi Wang","doi":"10.1111/ffe.14389","DOIUrl":"https://doi.org/10.1111/ffe.14389","url":null,"abstract":"<p>Creep damage assessment is crucial for ensuring the long-term reliability of key components operating at high temperatures. However, the existing studies on creep damage are mainly focused on constant loading conditions, while the effect of cyclic loading, which is a common loading mode in practice, remains unclear. In this paper, a series of stress-controlled cyclic creep tests on the Inconel 718 superalloy were performed to investigate the influence of cyclic loading on creep damage evolution. The ex-situ microstructural analyses, including fracture surface observations and EBSD measurements, were conducted to reveal the damage mechanisms under cyclic creep conditions. Furthermore, a cavity nucleation and growth model that accounts for the additional cavity closure was developed for the healing effect of cyclic creep damage evolution. The prediction results were consistent with the experimental data of cavity nucleation life and experimental life within a factor of 2.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3945-3960"},"PeriodicalIF":3.1,"publicationDate":"2024-07-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1111/ffe.14389","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142158674","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}
Mao Jiahao, Hirohata Mikihito, Xu Yifei, Chang Kyong-Ho
{"title":"Fatigue performance of bonding-assisted fillet weld roots by inserting adhesive material","authors":"Mao Jiahao, Hirohata Mikihito, Xu Yifei, Chang Kyong-Ho","doi":"10.1111/ffe.14400","DOIUrl":"10.1111/ffe.14400","url":null,"abstract":"<p>This study proposes a novel method to prevent fatigue cracks at the root of fillet welds in steel bridge supports by inserting epoxy resin as an adhesive material. A total of 36 specimens, categorized into welded-only and bonding-assisted types, were subjected to a series of four-point bending fatigue tests to simulate cyclic tensile stress conditions. Additionally, finite element analysis was employed to investigate the impact of epoxy insertion on stress distribution near the weld root. The results demonstrated that bonding-assisted specimens exhibited significantly improved fatigue life compared to welded-only specimens, with a notable reduction in tensile stress at the weld root. Furthermore, a displacement-based method was employed to evaluate weld root fatigue performance, yielding consistent results. These findings highlight the potential of integrating adhesive bonding in fillet welds to improve the durability and service life of steel bridge structures by effectively mitigating fatigue-related issues.</p>","PeriodicalId":12298,"journal":{"name":"Fatigue & Fracture of Engineering Materials & Structures","volume":"47 10","pages":"3646-3657"},"PeriodicalIF":3.1,"publicationDate":"2024-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1111/ffe.14400","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141805539","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}