{"title":"Derivation of fatigue damage law for an aluminum alloy based on plastic-creep separation strain analysis","authors":"Towa Hayashibe , Ken-ichi Ohguchi , Katsuhiko Sasaki , Kohei Fukuchi , Shinya Honda , Yorimasa Tsubota , Takuro Mita , Wataru Nagai , Kouji Ohsato , Nobuaki Shinya","doi":"10.1016/j.ijfatigue.2025.108964","DOIUrl":"10.1016/j.ijfatigue.2025.108964","url":null,"abstract":"<div><div>Aluminum (Al) alloys used for automobile engine components are subjected to fatigue loading at high temperatures over 1/2 of their melting temperatures <span><math><msub><mrow><mi>T</mi></mrow><mrow><mi>m</mi></mrow></msub></math></span>. The fatigue damage must be evaluated by a method that considers the effect of both the plastic and creep deformations because creep deformation occurs in the fatigue process at 1/2<span><math><msub><mrow><mi>T</mi></mrow><mrow><mi>m</mi></mrow></msub></math></span>. In this paper, the plastic-creep separation method is first applied to a casting Al alloy subjected to low cycle fatigue (LCF) loading, and a fatigue damage law is derived considering the effect of the plastic and creep damages on the fatigue life. Since Al alloy engine components are used at cyclically changing temperatures from room temperature to over 1/2<span><math><msub><mrow><mi>T</mi></mrow><mrow><mi>m</mi></mrow></msub></math></span>, the fatigue damage law is adapted to the fatigue life due to cyclic thermal loading employing temperature-dependence parameters. Finally, the fatigue damage law is applied to the fatigue life evaluation for the thermo-mechanical fatigue (TMF) test that reproduces a real used condition of engines.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108964"},"PeriodicalIF":5.7,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829264","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}
Michael Fitzka , Roman Morgenstern , Robert Willard , Andreas Hörauf , Philipp Koch , Bernd M. Schönbauer , Herwig Mayer
{"title":"Ultrasonic fatigue testing in hot hydrogen gas","authors":"Michael Fitzka , Roman Morgenstern , Robert Willard , Andreas Hörauf , Philipp Koch , Bernd M. Schönbauer , Herwig Mayer","doi":"10.1016/j.ijfatigue.2025.108991","DOIUrl":"10.1016/j.ijfatigue.2025.108991","url":null,"abstract":"<div><div>A novel ultrasonic fatigue testing setup has been developed for performing high and very high cycle fatigue tests in hot hydrogen gas at elevated pressures. The setup consists of a hydrogen pressure chamber containing the specimen, which is mounted and sealed at a node of the ultrasonic load train. Quenched and tempered 42CrMo4 steel is tested in hydrogen gas at 400 °C and 35 bar, as well as in hot air at 400 °C for comparison. Tests were performed at a load ratio of <em>R</em> = –1 with specimens containing artificial surface defects of ø100 µm to reduce scatter in fatigue lives. A fatigue limit is observed in hot air but not in hot hydrogen. Failures in hot hydrogen were found at 63 % of the lowest stress amplitude leading to failure in hot air. Fracture surfaces after testing in hot hydrogen appear rough and uneven with secondary cracks and small voids, whereas they are much smoother after fracture in hot air. Hydrogen embrittlement by hot hydrogen gas is clearly visible in ultrasonic fatigue testing, making this method highly useful for rapid material screening and comparison.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108991"},"PeriodicalIF":5.7,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815927","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}
Jiahao Cheng , Daniel Ryan , Brandon Kemerling , Patxi Fernandez-Zelaia , Sudhakar Bollapragada , Tyler Boveington , Michael M. Kirka
{"title":"Modeling low cycle fatigue (LCF) of additively manufactured Hastelloy X using An accelerated crystal plasticity fatigue damage model","authors":"Jiahao Cheng , Daniel Ryan , Brandon Kemerling , Patxi Fernandez-Zelaia , Sudhakar Bollapragada , Tyler Boveington , Michael M. Kirka","doi":"10.1016/j.ijfatigue.2025.108980","DOIUrl":"10.1016/j.ijfatigue.2025.108980","url":null,"abstract":"<div><div>This paper presents a microstructure-based model for low cycle fatigue (LCF) behavior and life of Nickel-based alloy Hastelloy X manufactured using laser-powder bed fusion (L-PBF) additive manufacturing (AM). AM Hastelloy X, a solution-strengthened alloy, is tested at elevated temperature under fully reversed LCF conditions at different strain levels. A generalized plane strain finite element model is generated from electron backscatter diffraction (EBSD) characterization. The constitutive behavior of the material under fatigue is modeled using crystal plasticity and calibrated with both monotonic tensile and cyclic stress–strain data. The fatigue micro-crack initiation and propagation in the microstructure is modeled using a modified Chaboche fatigue damage model. An embedded boundary condition with a homogenous medium is used to apply the cyclic deformation and prevent numerically introduced over-constraints during fatigue simulation. A ‘cycle-jump’ method is used to accelerate the fatigue simulation and reduce the computational cost. The simulation results are compared to LCF experiments, showing satisfactory matches in cyclic stress behavior and number of cycles to macro-crack initiation for all applied strain ranges. In addition, the model illustrates the potential for quantifying microscale fatigue life impacting factors such as microstructure and surface roughness, which is needed to accurately quantify the reliability of AM components in service.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108980"},"PeriodicalIF":5.7,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143807633","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}
Rong Chen , Gao-Ming Zhu , Ming-Liang Zhu , Fu-Zhen Xuan
{"title":"Correlation of slip behavior, strain evolution and fatigue crack growth retardation","authors":"Rong Chen , Gao-Ming Zhu , Ming-Liang Zhu , Fu-Zhen Xuan","doi":"10.1016/j.ijfatigue.2025.108974","DOIUrl":"10.1016/j.ijfatigue.2025.108974","url":null,"abstract":"<div><div>To evaluate the intrinsic mechanisms underlying fatigue crack growth retardation behavior, crack initiation and early growth behavior at the notch were monitored using in-situ SEM in a magnesium alloy. The evolution of crack-tip plastic strain and the associated microstructural damage were quantitatively characterized by EBSD and DIC. Results demonstrate that the crack growth rate followed a V-shaped pattern of decreasing before increasing, which could be correlated with strain field and slip activation. The strain decreasing zone was found originated from dynamic transfer of compressive strain near the crack-tip, while the strain appeared a positive correlation with fatigue crack growth rate in both retardation and recovery regimes. Both the retardation and recovery processes were grain orientation dependent, and the transition to recovery was assisted by the enhanced basal slip transfer. The findings offer a novel perspective on transient cracking behavior, guiding the fatigue-resistant design of magnesium alloys.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108974"},"PeriodicalIF":5.7,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143807740","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}
Mingsan Chen , Chong Wang , Sen Tang , Wenyu Zhong , Bo Xu , Xiaoming Bai , Kaikai Shi , Qingyuan Wang
{"title":"The effect and general relation of loading frequency on fatigue life of 316L stainless steel","authors":"Mingsan Chen , Chong Wang , Sen Tang , Wenyu Zhong , Bo Xu , Xiaoming Bai , Kaikai Shi , Qingyuan Wang","doi":"10.1016/j.ijfatigue.2025.108976","DOIUrl":"10.1016/j.ijfatigue.2025.108976","url":null,"abstract":"<div><div>The frequency effect constitutes a key issue in the acceleration technology of high cycle fatigue testing. In this study, fatigue tests were conducted on an austenitic steel at frequencies of 600 Hz, 1 kHz by vibration fatigue, and 20 kHz ultrasonic bending fatigue up to high cycle regime, respectively. The gauge section and loading form of the specimen were designed in the same condition to avoid influence from the volume effect and stress state, and to ensure the fatigue data are fully comparable. The results demonstrated that the fatigue properties were significantly affected by frequencies. Nevertheless, fractographic analysis revealed that the fracture mechanism remained the same. Therefore, we established a correlation between the frequency and the parameters of the Basquin formula, which was found suitable to predict fatigue life for results in articles with other frequencies. Subsequently, a general life prediction model was provided with improved accuracy by accounting for the impact of strain rate and temperature rise in different frequencies. In this model, the fatigue life under a given frequency and loading amplitude could be effectively predicted merely by using the fatigue data at 20 kHz, which means that the model may applied to convert data on the fatigue life among different frequencies.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108976"},"PeriodicalIF":5.7,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143820407","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}
Ateeb Ahmad Khan , Indra Vir Singh , Bhanu Kumar Mishra , Ramadas Chennamsetti
{"title":"A novel experimental method to evaluate the fatigue behaviour and damage evolution of bi-directional composites under variable amplitude loading","authors":"Ateeb Ahmad Khan , Indra Vir Singh , Bhanu Kumar Mishra , Ramadas Chennamsetti","doi":"10.1016/j.ijfatigue.2025.108979","DOIUrl":"10.1016/j.ijfatigue.2025.108979","url":null,"abstract":"<div><div>This study presents a novel experimental approach to evaluate the fatigue performance of bi-directional glass fiber-reinforced polymer (GFRP) composites under variable amplitude sequential block loading conditions. The proposed method incorporates advanced loading protocols to simulate realistic service conditions, capturing the complex nonlinear stress interactions and damage progression unique to composite materials. The experimental setup ensures precise control over load sequences and stress blocks, facilitating a comprehensive understanding of fatigue performance and failure mechanisms based on fatigue life, stiffness degradation and thermal response. Results demonstrate a significant influence of load sequence, cycle mixing and stress level on fatigue behaviour, providing critical insights into material performance and damage evolution. Key findings highlight the pronounced effect of high-to-low (H-L) compared to low-to-high (L-H) loading regimes on fatigue performance, showing up to 38 % reduced fatigue life. The study also demonstrates the influence of crack initiation and propagation rates on fatigue performance under both loading regimes. A load sequence sensitive damage law has been proposed to capture the nonlinear damage accumulation under variable loading conditions. This work provides a robust framework for improving the design and reliability of GFRP composites subjected to variable amplitude loading in engineering applications.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108979"},"PeriodicalIF":5.7,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815926","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}
Chenyu Zhao , Lisheng Deng , Shuang Wu , Weijie Wu , Yawei Peng , Xiaowei Wang , Yong Jiang , Jianming Gong
{"title":"Dual role of hydrogen in fatigue life of 316L austenitic stainless steel","authors":"Chenyu Zhao , Lisheng Deng , Shuang Wu , Weijie Wu , Yawei Peng , Xiaowei Wang , Yong Jiang , Jianming Gong","doi":"10.1016/j.ijfatigue.2025.108975","DOIUrl":"10.1016/j.ijfatigue.2025.108975","url":null,"abstract":"<div><div>The presence of hydrogen can significantly alter the fatigue behavior of materials, posing a serious threat to the safe and reliable operation of components. In this study, an electrochemical in-situ hydrogen charging fatigue testing method was used to examine the effect of hydrogen on the fatigue strength and lifetime of 316L austenitic stainless steel. The impact of hydrogen on fatigue fracture behavior was analyzed using scanning electron microscopy (SEM) and electron backscattered diffraction (EBSD). The results indicated that, compared to specimens tested in air, in-situ charging increases the fatigue lifetime at higher stress amplitudes but significantly reduces it at lower stress amplitudes. Regardless of the testing environment, the crack initiation lifetime constitutes the majority of the total fatigue lifetime. Notably, at higher stress amplitudes, hydrogen greatly extends the fatigue crack initiation lifetime, whereas, at lower stress amplitudes, it has the opposite effect. This is attributed to the influence of hydrogen on dislocation motion patterns, which lowers the critical stress for dislocation plane slip. Hydrogen plays a dual role in the fatigue behavior of 316L steel.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108975"},"PeriodicalIF":5.7,"publicationDate":"2025-04-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143843689","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}
Zhilong Dong , Wenchun Jiang , Xuefang Xie , Shengkun Wang , Yu Wan , Xianjun Pei , Shan-tung Tu
{"title":"Transition-behavior of fatigue crack with variation of stress amplitude for SAF2205 steel: Effect of dual-phase imbalance caused by welding","authors":"Zhilong Dong , Wenchun Jiang , Xuefang Xie , Shengkun Wang , Yu Wan , Xianjun Pei , Shan-tung Tu","doi":"10.1016/j.ijfatigue.2025.108978","DOIUrl":"10.1016/j.ijfatigue.2025.108978","url":null,"abstract":"<div><div>This work explores the influence of dual-phase imbalance on fatigue micro-scale crack for SAF2205 steel welded joints under a wide range of stress amplitudes. A series of quasi in-situ fatigue experiments and kernel average misorientation (KAM) evolution were performed. The results reveal distinct transition-behavior of crack initiation and propagation with varying stress amplitudes. At high stress amplitudes, as load increases, crack initiation shifts from austenite grain or phase boundaries to ferrite grain boundaries due to transfer of deformation-bearing phase. The crack propagation is influenced by the angle between the direction of grain orientation, grain/phase boundaries and loading axis. However, at low stress amplitudes, the predominant deformation mechanism changed from dislocation slip to strain incompatibility between grain boundary austenite (GBA) and ferrite, ulteriorly leading to crack initiation. Crack propagation is deflected when encountering intragranular austenite (IGA) due to the obstruction by high-energy phase interfaces. In addition, based on crystal plasticity finite element model (CPFEM) and extended finite element method (XFEM), a fatigue life prediction model is further developed by considering the micro- crack damage behavior, enabling precise simulation of the transition-behavior in crack initiation sites, crack propagation direction as well as S-N distribution under varying stress amplitudes.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108978"},"PeriodicalIF":5.7,"publicationDate":"2025-04-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143807634","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}
Zhongkai Ren, Xiongwei Guo, Jinxiong Hou, Tao Wang, Qingxue Huang
{"title":"High cycle fatigue properties of Ti-6Al-4V/304 clad plate with corrugated interface under the influence of multi-factor coupling","authors":"Zhongkai Ren, Xiongwei Guo, Jinxiong Hou, Tao Wang, Qingxue Huang","doi":"10.1016/j.ijfatigue.2025.108966","DOIUrl":"10.1016/j.ijfatigue.2025.108966","url":null,"abstract":"<div><div>In this study, the high cycle fatigue properties of Ti-6Al-4V/304 clad plate with corrugated interface prepared by asymmetric rolling local strong stress (ARLSS) process and flat interface clad plate prepared by traditional flat roll rolling were compared and analyzed. The results show that the high cycle fatigue performance of Ti-6Al-4V/304 clad plate with corrugated interface is significantly higher than that of flat interface due to the difference of microstructure. During the fatigue test, the fracture modes of the clad plates with different interface morphologies were consistent. The damage first initiated and expanded on the side of 304 stainless steel. When the fatigue fracture of 304 stainless steel occurred, the Ti-6Al-4V was subjected to large uniaxial tensile stress and followed by tensile fracture, and the interface is not a weak area where fatigue damage occurs. Through finite element simulation and microstructure analysis, the results show that the trough position of 304 stainless steel side bears large stress, and there is large plastic deformation accumulation under cyclic load, which leads to γ-α’ phase transformation, and the resulting stress concentration becomes the key factor for fatigue failure in this area. This study not only confirms the role of residual stress in improving the fatigue performance of clad plates, but also enhances our understanding of the fatigue behavior of corrugated interface clad plates. Furthermore, it provides a scientific basis for the design and application of clad plates, particularly in evaluating their durability under high-cycle fatigue loads.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108966"},"PeriodicalIF":5.7,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785998","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}
Jianning Mai , Fulin Liu , Yao Chen , Chao He , Linsen Wang , Zhengbin Zhong , Wei Zhang , Hong Zhang , Chong Wang , Qingyuan Wang , Yongjie Liu
{"title":"High cycle fatigue properties, failure mechanisms and microstructure evolution of 9Cr3W3Co steel under different stress ratios at 650 °C","authors":"Jianning Mai , Fulin Liu , Yao Chen , Chao He , Linsen Wang , Zhengbin Zhong , Wei Zhang , Hong Zhang , Chong Wang , Qingyuan Wang , Yongjie Liu","doi":"10.1016/j.ijfatigue.2025.108971","DOIUrl":"10.1016/j.ijfatigue.2025.108971","url":null,"abstract":"<div><div>The study investigates the high cycle fatigue properties, failure mechanisms, and microstructure evolution of 9Cr3W3Co steel at 650 °C under stress ratios R of 0.1, 0.3 and 0.5. S-N curves exhibit a continuous decline, with corresponding fatigue strengths at 10<sup>7</sup> cycles of 116.6, 99.6 and 64.8 MPa for R of 0.1, 0.3 and 0.5, respectively. Surface or sub-surface crack initiation failure (SSCIF) is the only observed failure mode at R = 0.1, while necking induced failure (NIF) dominates at R = 0.5. At R = 0.3, both failure modes coexist. SSCIF mode is characterized by localized plastic deformation and fatigue damage accumulation, with crack propagation and facet formation influenced by the activation of slip systems with relatively high Schmid factors and the grain orientation and local deformation distribution of martensite structures. NIF mode is marked by widespread plastic deformation, void nucleation and coalescence, resulting in the rapid diminution of the effective load-bearing of specimens and ultimately leading to necking failure.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"198 ","pages":"Article 108971"},"PeriodicalIF":5.7,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815928","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}