Zheng-Xiang Shen , Sheng-Jie Qian , Hui-Yu Ji , Wei-Wei Ji , Bo Xu , Yang Zheng
{"title":"Early detection and monitoring of fatigue damage in medium carbon steel based on multi-micromagnetic NDT fusion method","authors":"Zheng-Xiang Shen , Sheng-Jie Qian , Hui-Yu Ji , Wei-Wei Ji , Bo Xu , Yang Zheng","doi":"10.1016/j.ijfatigue.2025.109069","DOIUrl":"10.1016/j.ijfatigue.2025.109069","url":null,"abstract":"<div><div>Based on stress-controlled fatigue tests of 45 carbon steel notched specimens, an in-situ comprehensive evaluation of fatigue damage evolution was accomplished via micromagnetic non-destructive testing techniques, and various magnetic parameters were then determined to describe the actual fatigue state. In general, the characteristics quantities extracted from magnetic hysteresis, Barkhausen noise and incremental permeability measurements exhibited a trend of initial oscillations during the early stages of fatigue, reflecting fatigue softening. As the load cycle increased, the magnetic parameters became stabilized and experienced drastic changes in the final stage before failure. Evidently, the dynamic dependence of fatigue magnetization behavior was related to the progressive accumulation of damage by the cyclic loading. Among those, the magnetic incremental permeability method was highly sensitive to the fatigue damage before a macroscopic crack was initiated. Particularly, the Mean eigenvalues of incremental permeability signals presented a nonlinear increment behavior, starting approximately from the 80 % of fatigue life, which could be used to assess the degree of damage quantitatively. Furthermore, the unique zero-crossing feature of Mean value at 94.2 % lifetime can serve as a warning for imminent fatigue failure of the component.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109069"},"PeriodicalIF":5.7,"publicationDate":"2025-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144123769","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 computational framework for predicting the effect of surface roughness in fatigue","authors":"Sara Jiménez-Alfaro , Emilio Martínez-Pañeda","doi":"10.1016/j.ijfatigue.2025.109044","DOIUrl":"10.1016/j.ijfatigue.2025.109044","url":null,"abstract":"<div><div>Surface roughness is a critical factor influencing the fatigue life of structural components. Its effect is commonly quantified using a correction coefficient known as the surface factor. In this paper, a phase field based numerical framework is proposed to estimate the surface factor while accounting for the stochastic nature of surface roughness. The model is validated against existing experimental data. Furthermore, we investigate the influence of key parameters on the fatigue life of rough surfaces, such as surface topology and failure strength. An important effect of surface roughness is observed when the average surface roughness increases and the correlation length of the surface profile decreases. This effect becomes more pronounced with higher failure strengths.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109044"},"PeriodicalIF":5.7,"publicationDate":"2025-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144138553","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}
Zhang Zhuzhu , Mao Haitao , Huang Hailiang , Wu Xingjun , Shen Pei , Liu Yulin
{"title":"Reliability analysis method for aircraft structure corrosion fatigue based on Chaboche model","authors":"Zhang Zhuzhu , Mao Haitao , Huang Hailiang , Wu Xingjun , Shen Pei , Liu Yulin","doi":"10.1016/j.ijfatigue.2025.109070","DOIUrl":"10.1016/j.ijfatigue.2025.109070","url":null,"abstract":"<div><div>A reliability analysis method for predicting the service life of aircraft structures considering corrosion damage has been proposed. This method introduces corrosion damage as the initial damage into the Chaboche fatigue cumulative damage model, and uses Monte Carlo method to simulate and reconstruct the corrosion fatigue damage process of the structure, achieving reliability analysis of the corrosion fatigue life of aircraft structures. To verify the effectiveness of the proposed method, SO<sub>2</sub> salt spray accelerated corrosion test and corrosion fatigue test were conducted on A100 steel as a case study, revealing the damage law and mechanism of A100 steel under corrosive environment and fatigue load. By establishing a Chaboche fatigue cumulative damage model for A100 steel and completing model parameter calibration, the reliability of structural corrosion fatigue life was evaluated using the proposed reliability method. This method can improve the maintainability and reliability requirements of aircraft structures in corrosive environments, providing a new approach for aircraft structure safety assessment, life monitoring, and life extension.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109070"},"PeriodicalIF":5.7,"publicationDate":"2025-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144147002","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}
Zhenyu Zhu , Hailong Kong , Yongyou Zhu , Mattias Calmunger , Guocai Chai , Qingyuan Wang , Wei Feng
{"title":"Pre-corrosion very-high-cycle AI-fatigue in completion string","authors":"Zhenyu Zhu , Hailong Kong , Yongyou Zhu , Mattias Calmunger , Guocai Chai , Qingyuan Wang , Wei Feng","doi":"10.1016/j.ijfatigue.2025.109068","DOIUrl":"10.1016/j.ijfatigue.2025.109068","url":null,"abstract":"<div><div>The very-high-cycle fatigue (VHCF) behavior of material BG2532, used in oil and gas completion strings, was investigated under both non-corrosive and hydrogen sulfide (H<sub>2</sub>S) gas corrosion conditions. During the experiment, the material’s fatigue property and fatigue fracture characteristics were studied. Additionally, the microstructure on the axial cross-section, perpendicular to the fatigue fracture surface, was analyzed to explore the mechanism of corrosion-induced VHCF crack initiation. To enable unified VHCF life prediction for the material under both corrosive and non-corrosive conditions, different VHCF life prediction models were developed. Fatigue fracture characteristics, including the number of grains per unit area on fatigue source and the facet ratio on propagation area, were proposed as key parameters for VHCF modeling. Two artificial intelligence (AI)-fatigue models incorporating corrosion effects were developed and compared. The results show that integrating fatigue source and propagation characteristics using deep learning and convolutional neural networks significantly enhances the accuracy of VHCF life predictions, with errors remaining within a factor of two. This model effectively predicts the VHCF life of BG2532 alloy under both corrosive and non-corrosive conditions.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109068"},"PeriodicalIF":5.7,"publicationDate":"2025-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144123768","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}
Grzegorz Glodek , Sanjay Gothivarekar , Brecht Van Hooreweder , Reza Talemi
{"title":"Investigating fretting fatigue response of additively manufactured Ti-6Al-4V in dovetail joint connections","authors":"Grzegorz Glodek , Sanjay Gothivarekar , Brecht Van Hooreweder , Reza Talemi","doi":"10.1016/j.ijfatigue.2025.109024","DOIUrl":"10.1016/j.ijfatigue.2025.109024","url":null,"abstract":"<div><div>Fretting generates surface damage at the contact interface of components under pressure subjected to small-magnitude, relative oscillatory motion. In the presence of bulk cyclic loading, fretting fatigue occurs, significantly reducing the lifetime of affected components, such as the dovetail joint connections in turbine blades. In this research, the fretting fatigue response of additively manufactured (AM) Ti-6Al-4V parts was studied, focusing on the dovetail geometry. A specialized test setup was developed to evaluate the resistance of the AM material to fretting fatigue conditions and compare its response to its conventionally manufactured counterpart. In parallel, a finite element (FE) model of the testing apparatus was created to provide deeper insights into the stress distribution at the contact interface. Results of the numerical simulations revealed that the most damaging mode of fretting fatigue, known as stick–slip, was achieved, closely resembling the conditions often observed in real-life industrial assemblies. The experimental results demonstrate that the tribomechanical fretting fatigue response of AM-Ti64 aligns with that of the conventionally manufactured material. While AM-Ti64 exhibits better crack propagation resistance, it is more prone to fretting damage. However, the AM material is hindered by near-surface internal defects, such as lack-of-fusion-induced voids and porosities, which form during the manufacturing process. These defects act as stress concentrators, leading to early failures outside the contact zone.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109024"},"PeriodicalIF":5.7,"publicationDate":"2025-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144099104","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}
Jiakai Shu , Zhongqiu Fu , Xincheng Li , Bohai Ji , Qiudong Wang
{"title":"Full-range fatigue life prediction of deck-rib welds based on hybrid physics-informed and data-driven model","authors":"Jiakai Shu , Zhongqiu Fu , Xincheng Li , Bohai Ji , Qiudong Wang","doi":"10.1016/j.ijfatigue.2025.109061","DOIUrl":"10.1016/j.ijfatigue.2025.109061","url":null,"abstract":"<div><div>A full-range fatigue life prediction model based on a hybrid physics-informed and data-driven model (HPDM) specifically for the deck-rib welds of orthotropic steel decks (OSDs) is proposed. A physical information framework was established, which considers the effective notch stress concentration factors caused by weld geometry, different mean stress correction models, and welding residual stresses. Subsequently, the full-range S-N curves that cover all key fatigue behavior regions of materials constructed by the framework serve as the physical constraints of HPDM, combining physical information with experimental data. The collected fatigue test data were adjusted according to the physical information framework for validation. The results indicate that the proposed improved HPDM outperforms traditional S-N curve HPDM based on the Basquin relationship, and that employing the Goodman method for mean stress correction yields better fitting and generalization performance.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109061"},"PeriodicalIF":5.7,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144070731","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}
Ke Chen , Jia Huang , Chao Zhang , Yong Chen , YuLong Li
{"title":"Self-heating and acoustic emission guided fatigue damage evolution analysis and rapid life prediction for thermoplastic composite ultrasonic welds","authors":"Ke Chen , Jia Huang , Chao Zhang , Yong Chen , YuLong Li","doi":"10.1016/j.ijfatigue.2025.109032","DOIUrl":"10.1016/j.ijfatigue.2025.109032","url":null,"abstract":"<div><div>With the increasing usage of thermoplastic composites, ultrasonic welding has become a critical joining technique owing to its superior performance. However, due to the heterogeneity of the welded joint, the damage evolution mechanism is complex and hard to predict its fatigue performance. In this paper, the fatigue damage evolution behavior of CF/PEEK ultrasonic welded joints is systematically investigated by combining Infrared Thermography (IRT) and Acoustic Emission (AE) data. The results reveal that both the frequency and amplitude of AE signals significantly increase with the loading amplitude, accompanied by a noticeable temperature rise on the specimen surface. By applying K-means clustering to AE amplitude data, three damage modes during the fatigue failure process are identified. Furthermore, the fatigue damage evolution process of the joints is analyzed in conjunction with optical microscopy observations. Based on K-means clustering and Miner’s Rule, a fatigue life prediction model utilizing AE data is developed. Compared with traditional fatigue test results, the predicted fatigue limit exhibits an error of only 1.07%, and the predicted S-N curve falls within the 95% confidence band of the experimental S-N curve. This study provides both theoretical and experimental support for the fatigue life prediction of CF/PEEK ultrasonic welded joints.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109032"},"PeriodicalIF":5.7,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144070732","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}
Aditya Khanna , James Vidler , Michael Bermingham , Andrew Sales , Ling Yin , Andrei Kotousov
{"title":"A compliance-based method for correcting fatigue crack growth data in the presence of residual stresses","authors":"Aditya Khanna , James Vidler , Michael Bermingham , Andrew Sales , Ling Yin , Andrei Kotousov","doi":"10.1016/j.ijfatigue.2025.109066","DOIUrl":"10.1016/j.ijfatigue.2025.109066","url":null,"abstract":"<div><div>Variations of residual stress fields in a fatigue test specimen and/or across specimens influence the fatigue crack growth rate measurements. Therefore, these variations can contribute significantly to the scatter of fatigue properties obtained on specimens, such as additively manufactured specimens without stress relief, specifically at low stress intensity factor range. To address this problem, a new compliance-based method is developed for correcting fatigue crack growth data in the presence of a residual stress fields of variable magnitude. It is based on the theoretical modelling of the propagation of an edge crack in an elasto-plastic material subjected to cyclic loading of a constant amplitude. The method is demonstrated for compact tension super duplex stainless steel (SDSS) and aluminium specimens tested without post-fabrication heat treatment. The method can be applied for both the evaluation of residual stress fields in fatigue specimens and obtaining the intrinsic fatigue properties of materials.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109066"},"PeriodicalIF":5.7,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144089421","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}
Angelo Savio Calabrese , Anastasios P. Vassilopoulos
{"title":"On the fatigue behavior of thin and thick adhesively bonded composite joints","authors":"Angelo Savio Calabrese , Anastasios P. Vassilopoulos","doi":"10.1016/j.ijfatigue.2025.109065","DOIUrl":"10.1016/j.ijfatigue.2025.109065","url":null,"abstract":"<div><div>Investigations of the fatigue performance of adhesively bonded joints were initiated since the 1950 s. An abundance of publications has emerged dealing with the experimental investigation of the fatigue performance of adhesively bonded joints of various geometries and material combinations to serve the needs of various structures operating under various loading and environmental conditions. This work reviews the fatigue of composite adhesively bonded joints by analyzing relevant literature and reviewing current testing standards for primary applications. It classifies joints based on the materials used and the bondline thickness moving from thin film adhesive joints to thick paste adhesive joints to cover a wide range of contemporary engineering applications. The findings lead to a comprehensive discussion that lays the groundwork for further research in this field.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109065"},"PeriodicalIF":5.7,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144117084","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":"Investigation of the pitting-to-crack transition in corrosion-fatigue of high-strength steel wires based on the phase-field method","authors":"Haonan Bing , Shunlong Li , Chengming Lan","doi":"10.1016/j.ijfatigue.2025.109040","DOIUrl":"10.1016/j.ijfatigue.2025.109040","url":null,"abstract":"<div><div>This study develops a coupled corrosion-fatigue phase-field model to investigate the pitting-to-crack transition in high-strength steel wires by integrating chemical–electrochemical processes and cyclic loading effects within a unified computational framework. The corrosion-fatigue life (CFL) of high-strength steel wires was determined through coupled corrosion-fatigue experiments, and the phase-field model replicated the observed CFL trends, demonstrating its accuracy and reliability in predicting material degradation. The model effectively captures the entire evolution from pit nucleation to crack propagation. Simulation results show that pit geometry plays a critical role in the transition from corrosion-driven degradation to mechanically dominated crack propagation, with narrower pits generating higher stress concentrations that accelerate crack initiation. Additionally, the interfacial kinetic coefficient significantly influences pit evolution and crack nucleation, underscoring its importance in the progression of corrosion-fatigue damage. The study also identifies the critical energy release rate (<span><math><msub><mrow><mi>G</mi></mrow><mrow><mi>c</mi></mrow></msub></math></span>) as a key mechanical parameter that governs the transition from pitting to fatigue crack growth, providing a quantitative criterion for assessing damage evolution. The proposed phase-field model offers a comprehensive tool for predicting structural degradation in high-strength steel wires and provides fundamental insights into corrosion-fatigue mechanisms.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109040"},"PeriodicalIF":5.7,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144083902","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}