{"title":"The effect of corrosion on the fatigue crack-growth of 17-4 PH stainless steel specimens made by selective laser melting","authors":"America Califano , Enrico Armentani , Filippo Berto , Raffaele Sepe","doi":"10.1016/j.ijfatigue.2025.109059","DOIUrl":"10.1016/j.ijfatigue.2025.109059","url":null,"abstract":"<div><div>The numerous advantages of the Selective Laser Melting (SLM) technology have made it a quite common Additive Manufacturing (AM) process for components made in metals and metallic alloys. Several factors, like building direction, defects, residual stresses and corrosion can substantially jeopardize the performance of the finished products obtained with such manufacturing process. In this regard, the present study investigates the impact of corrosion on the fatigue crack-growth behavior of 17-4 PH stainless steel specimens manufactured through SLM. This type of stainless steel, known for its high strength and corrosion resistance, is widely used in applications requiring durability under cyclic loading. For this reason, this work explores how the experimental crack initiation and propagation rates are affected by two cross different orientations of the initial notch (horizontal and vertical), different testing environments (air and seawater) and different load frequencies. Findings also highlight how corrosion accelerates fatigue crack growth in SLM-fabricated specimens, indicating a need for tailored post-processing treatments to enhance their performance in corrosive environments.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109059"},"PeriodicalIF":5.7,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143947693","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}
Tim Brömer , Viktor Widerspan , Sulaiman Shojai , Elyas Ghafoori
{"title":"Enhanced local fatigue approach for welded tubular joints using 3D digital scans and implicit gradient model","authors":"Tim Brömer , Viktor Widerspan , Sulaiman Shojai , Elyas Ghafoori","doi":"10.1016/j.ijfatigue.2025.109060","DOIUrl":"10.1016/j.ijfatigue.2025.109060","url":null,"abstract":"<div><div>The design of jacket structures in offshore wind turbines (OWTs) is driven by fatigue, crucial due to dynamic loads from operational movements, waves, and wind. This study aims to develop a digital framework for fatigue analysis of tubular welded joints in jacket OWT, incorporating real 3D scanned geometries and imperfections through their digital images. Numerical analysis has been conducted using finite element method to predict the experimental results, in which the effect of micro-support has been taken into account using an implicit gradient model (IGM). Furthermore, 4R method has been used to account for mean stress corrections due to residual stresses and imperfections. Digital Image Correlation (DIC) was employed during the high-cycle fatigue experiments to detect the initiation and progression of a technical crack, providing precise measurements of strain distribution and crack size development. The results have shown that the proposed numerical framework based on the IGM can successfully determine the lifetime and location of crack initiation in the 3D scanned welded details. The proposed framework significantly improves the accuracy of high-cycle fatigue life predictions and offers a scalable solution for structural health monitoring, facilitating lifetime extension across a wide range of industries, including construction, automotive, aerospace, and renewable energy.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109060"},"PeriodicalIF":5.7,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144123767","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}
Bo Dong , Tang Gu , Yong Zhang , Henry Proudhon , Yun–Fei Jia , Xian–Jun Pei , Xu Long , Fu–Zhen Xuan
{"title":"Interpretable prediction of sample size–dependent fatigue crack formation lifetime using deep symbolic regression and polycrystalline plasticity models","authors":"Bo Dong , Tang Gu , Yong Zhang , Henry Proudhon , Yun–Fei Jia , Xian–Jun Pei , Xu Long , Fu–Zhen Xuan","doi":"10.1016/j.ijfatigue.2025.109057","DOIUrl":"10.1016/j.ijfatigue.2025.109057","url":null,"abstract":"<div><div>Fatigue Indicator Parameters (FIPs), derived from cyclic intragranular and intergranular mechanical variables using the Crystal Plasticity Finite Element Method (CPFEM), can serve as surrogate measures of the driving force for fatigue crack formation within the first grain or nucleant phase. Simulating larger sample (i.e., increasing the number of grains) using CPFEM generally result in higher maximum FIP values, indicating a greater likelihood of fatigue crack initiation. However, the substantial computational demands of CPFEM limit its practical application in investigating the sample size effect on maximum FIPs. This study employs the recently developed Deep Symbolic Regression (DSR) algorithm to generate interpretable expressions linking sample size with the statistical characteristics of maximum FIPs in duplex Ti–6Al–4 V with random texture. These data–driven expressions obtained through DSR are systematically compared with predictions derived from the statistically grounded Extreme Value Theory (EVT), which suggests that the entire FIP dataset exceeding a threshold <em>x</em><sub>0</sub> converges to Gumbel distribution. The strong agreements found between DSR and EVT expressions not only validates the mathematical underpinnings of EVT but also demonstrates how EVT can elucidate the physical insights revealed by DSR. Building on this, we introduce a novel method, i.e., Regrouping of Maximum FIPs (RMF), to improve prediction reliability by mitigating the influence of the threshold <em>x</em><sub>0</sub> in EVT. Finally, by leveraging the statistical distribution of maximum FIPs derived from DSR, we forecast the sample size–dependent Fatigue Crack Formation Lifetime (FCFL), providing a robust tool for engineering applications.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109057"},"PeriodicalIF":5.7,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144068577","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}
Xiyuan Zhang , Dasheng Wei , Mengdi Ma , Shun Yang
{"title":"The effect of interfacial contact and damage gradient on fretting fatigue of Ti-6Al-4 V dovetail assembly using a multiaxial fatigue framework","authors":"Xiyuan Zhang , Dasheng Wei , Mengdi Ma , Shun Yang","doi":"10.1016/j.ijfatigue.2025.109058","DOIUrl":"10.1016/j.ijfatigue.2025.109058","url":null,"abstract":"<div><div>In this study, fretting fatigue tests were performed on dovetail assemblies. The displacement and strain of the components during testing were recorded using Digital Image Correlation (DIC) equipment. The results revealed that the dovetail assembly gradually exhibited a sticking phenomenon, stabilizing after approximately 10,000 cycles, with relative slip significantly reduced compared to the initial cycles. Surface wear and temperature were also monitored. The findings showed that during the fretting tests, a considerable amount of wear debris accumulated in the contact zone, increasing the coefficient of friction (COF) and intensifying the sticking phenomenon. This led to reduced frictional energy, causing minimal changes in surface temperature. Consequently, for fretting fatigue in dovetail assemblies, localized stress concentration emerged as the primary factor affecting fatigue life, surpassing influences from relative slip, surface wear, and frictional heat generation. Additionally, a finite element model of the dovetail assembly was developed, incorporating the Chaboche material constitutive model to calculate the stable stress–strain distribution under cyclic loading. The model’s predictions were validated against the DIC test results. Based on an established multiaxial fatigue framework, a program was developed to post-process the simulation results, producing diagrams for critical angles and damage distribution. To address the characteristics of local damage gradients, a method for selecting the critical distance and applying damage gradient correction was proposed. This approach was successfully applied to the SWT and FS models, demonstrating excellent validation.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109058"},"PeriodicalIF":5.7,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143935591","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}
Jothi S.M.L. Narasimhan , Farshid Sadeghi , Ben Wang , Chinpei Wang
{"title":"Effects of residual stress on rolling contact fatigue of ductile iron","authors":"Jothi S.M.L. Narasimhan , Farshid Sadeghi , Ben Wang , Chinpei Wang","doi":"10.1016/j.ijfatigue.2025.109055","DOIUrl":"10.1016/j.ijfatigue.2025.109055","url":null,"abstract":"<div><div>This study investigates the rolling contact fatigue (RCF) behavior of ductile iron (DI) using experimental and analytical method. The fatigue behavior of DI was assessed under both torsion fatigue and RCF. The RCF of DI was assessed by a 3 ball-on-rod test rig at a peak pressure of 3.6 GPa. Torsion fatigue tests were performed using an MTS test setup to determine the material’s stress-life (S-N) response. A Rockwell hardness tester was utilized to determine the global hardness of DI materials, while a nano indenter was employed to obtain the hardness distribution along the depth of the DI RCF rods. X-ray diffraction (XRD) was employed to measure the residual stresses prior to and after RCF testing to assess the effect of residual stresses on fatigue life. XRD results revealed a 32% increase in compressive residual stress after RCF testing, suggesting plastic induced residual stresses, which in turn enhanced fatigue resistance. In order to further validate the experimental findings; a continuum damage mechanics finite element (CDM-FE) model was employed for fatigue life prediction. The material constants used in the damage evolution equation of the CDM framework were obtained using torsion fatigue S-N data. Different residual stress profiles as a function of the depth of the material were incorporated into the model, and the corresponding RCF life predictions were evaluated. The analytical results demonstrated good corroboration with the experimental results, confirming the significance of residual stress in influencing fatigue performance. A two-parameter Weibull distribution was utilized to characterize the DI material’s probability of failure, demonstrating that its RCF performance is in par but slightly lower to that of high-strength steel.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109055"},"PeriodicalIF":5.7,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144068576","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":"Simultaneously improving corrosion and fatigue resistance of A100 steel by laser assisted ultrasonic nanocrystal surface modification","authors":"Weidong Zhao , Yalin Dong , Chang Ye , Jingwei Zhao","doi":"10.1016/j.ijfatigue.2025.109056","DOIUrl":"10.1016/j.ijfatigue.2025.109056","url":null,"abstract":"<div><div>This study employs a cutting-edge process known as laser-assisted ultrasonic nanocrystal surface modification (LA-UNSM) to form a surface composite gradient deformation layer on A100 ultra-high strength steel to harmonize its corrosion and fatigue characteristics. The results revealed that the innovative method softened the sample surface via laser preheating, while the ultrasonic impact forged a composite gradient deformation layer consisting of oxides, low-angle grain boundaries, densely packed dislocations, and refined grains. Concurrently, the dual-action of laser preheating and ultrasonic impact imprinted a gradient-hardened layer approximately 200 μm deep, and a compressive residual stress field extending up to 420 μm. By forming the composite gradient deformation layer and compressive residual stress field, LA-UNSM notably solved the contradiction between corrosion and fatigue properties.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109056"},"PeriodicalIF":5.7,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143928694","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}
Sina Safari , Diogo Montalvão , Pedro R. da Costa , Luís Reis , Manuel Freitas
{"title":"Statistical calibration of ultrasonic fatigue testing machine and probabilistic fatigue life estimation","authors":"Sina Safari , Diogo Montalvão , Pedro R. da Costa , Luís Reis , Manuel Freitas","doi":"10.1016/j.ijfatigue.2025.109028","DOIUrl":"10.1016/j.ijfatigue.2025.109028","url":null,"abstract":"<div><div>A new statistical technique is proposed to quantify the experimental uncertainty observed during ultrasonic fatigue testing of metals and its propagation into the stress-lifetime predictive curve. Hierarchical Bayesian method is employed during the calibration and operation steps of ultrasonic fatigue testing for the first time in this paper. This is particularly important due to the significant dispersion observed in stress-life data within the high and very high cycle fatigue regimes. First, the measurement systems, including displacement laser readings and high-speed camera system outputs, are cross-calibrated. Second, a statistical learning approach is applied to establish the stress-deformation relationship, leveraging Digital Image Correlation (DIC) measurements of strain and laser displacement measurements at the ultrasonic machine specimen’s tip. Third, an additional hierarchical layer is introduced to infer the uncertainty in stress-life curves by incorporating learned stress distributions and the distribution of fatigue failure cycles. The results identify key sources of uncertainty in UFT and demonstrate that a hierarchical Bayesian approach provides a systematic framework for quantifying these uncertainties.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109028"},"PeriodicalIF":5.7,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143931975","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}
Xiongfeng Ruan , Burak Karabulut , Jelena Dobrić , Barbara Rossi
{"title":"Generalised notch stress method to evaluate the fatigue behaviour of rough and smooth wire arc additively manufactured components","authors":"Xiongfeng Ruan , Burak Karabulut , Jelena Dobrić , Barbara Rossi","doi":"10.1016/j.ijfatigue.2025.109045","DOIUrl":"10.1016/j.ijfatigue.2025.109045","url":null,"abstract":"<div><div>The fatigue life of components under cyclic loading is highly sensitive to surface conditions, as imperfections lead to stress concentrations and early fatigue crack initiation. This study investigates the fatigue performance of both rough and smooth specimens made from S355 low-alloy carbon steel using a cold metal transfer (CMT)-based wire arc additive manufacturing (WAAM) process. Three types of specimens (machined, sinuous and raster specimens) with different surface geometries are fabricated. Rough fatigue coupons are cut using waterjet cutting from the as-deposited walls while keeping the rough surface unmachined. The geometric properties of rough fatigue coupons are quantified by a 3D laser scanner, followed by static tensile tests, hardness measurements and fatigue tests. Fatigue crack initiation and propagation for different surface types are analysed under scanning electron microscopy (SEM). Several computational methods, including the numerical local fatigue stress evaluation, the hot spot stress method and the effective notch stress method, are analysed for their effectiveness in assessing the fatigue resistance of rough specimens. A generalised notch stress method based on notch stress theory is proposed and validated. Our results prove that the fatigue performance of specimens with different surface conditions can be unified using the proposed generalised notch stress method.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109045"},"PeriodicalIF":5.7,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143923064","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":"Improvement of fatigue performance of low-alloy steels with a sulfurized layer using fine particle peening as pre-treatment under rotating bending","authors":"Shotaro Noguchi , Kiyotaka Mitake , Shinichiro Kurosaka , Kosuke Doi , Hisashi Harada , Shoichi Kikuchi","doi":"10.1016/j.ijfatigue.2025.109043","DOIUrl":"10.1016/j.ijfatigue.2025.109043","url":null,"abstract":"<div><div>The influence of a hybrid surface modification combining fine particle peening (FPP), which is defined as peening using particles less than 200 μm in diameter, and sulfurizing on the fatigue properties of low-alloy steels (AISI4120) were investigated. Three types of sulfurized samples were prepared by electrochemical polishing and FPP with iron(II) sulfide (FeS) particles or steel particles as a pre-treatment. Fatigue tests were conducted under rotating bending to evaluate the fatigue performance of sulfurized specimens pre-treated with FPP in ambient air. FPP using steel particles increased the fatigue limit of specimens treated with sulfurizing. Moreover, residual stress was measured using the cos<em>α</em> method before and after fatigue tests under constant stress amplitude to examine the mechanism by which the fatigue limit increases considering residual stress relaxation. In addition, the microstructure of surface-modified specimens was analysed using electron backscattered diffraction and X-ray diffraction. Fine crystal grains were formed by FPP; however, the fine-grained layer formed by FPP using FeS particles disappeared during the subsequent sulfurizing. By contrast, fine grains formed by FPP using steel particles remained during the following sulfurizing, which resulted in an improvement of the fatigue performance of sulfurized steels.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109043"},"PeriodicalIF":5.7,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143913228","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 theoretical model for three-dimensional fatigue crack closure and growth under variable amplitude loadings","authors":"Pengfei Cui , Jianqiang Zhang , Wanlin Guo","doi":"10.1016/j.ijfatigue.2025.109042","DOIUrl":"10.1016/j.ijfatigue.2025.109042","url":null,"abstract":"<div><div>Fatigue crack closure (FCC) and growth (FCG) behavior under variable amplitude loading (VAL) are ubiquitous in engineering structures. With the plasticity-induced cack closure concept, Budiansky and Hutchinson (1978) pioneered the analytical FCC model under plane stress state and constant amplitude loading (CAL) conditions with stress ratio <em>R</em> ≥ 0. Here, we developed the analytical model into three-dimensional (3D) FCC and FCG under VAL, by which the FCG life under CAL as well as VAL can be predicted only based on the FCG data from the standard CAL testing, and free from any empirical parameters. Under CAL, the present model shows that the opening-stress ratio increases with increasing stress ratio and decreases with increasing applied maximum stress and 3D constraint levels, in good agreement with finite element and experimental data from the literature. Validations against one hundred and thirty-three experiments available from the literature, including eight materials and three types of specimens with through-the-thickness and surface cracks, show that the predicted FCG life is within 0.4 to 2.5 times of the experimental results under both CAL and VAL. It is found that the coupling effects of stress ratio, 3D constraint, applied maximum stress and load history on FCC and FCG can be effectively unified by the present theoretical model.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"199 ","pages":"Article 109042"},"PeriodicalIF":5.7,"publicationDate":"2025-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143913235","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}