{"title":"Effects of stress ratio on small crack growth behavior in titanium alloys with different microstructures under corrosion fatigue condition","authors":"Le Chang , Xingyu Ren , Hongpeng Xie , Changyu Zhou","doi":"10.1016/j.ijfatigue.2025.109257","DOIUrl":"10.1016/j.ijfatigue.2025.109257","url":null,"abstract":"<div><div>This study systematically examines the influence of corrosion on small crack growth in TC4 ELI titanium alloys with equiaxed, bimodal, and lamellar microstructures under varying stress ratios. At low stress ratios, corrosion-induced crack tip blunting was found to retard crack propagation and extend fatigue life. Conversely, at high stress ratios, the increased crack tip opening promotes Cl<sup>−</sup> ingress, accelerating crack growth and significantly reducing fatigue resistance. Elevated current densities further amplify corrosion-driven crack growth. Corrosive environments also weaken the microstructural effects on crack propagation, as evidenced by reduced crack deflection, straighter crack paths, and alterations in the dominant slip systems near the crack tip. Among the microstructures, lamellar structures exhibit more severe corrosion damage under high stress ratios than equiaxed or bimodal ones. Finally, by incorporating the total charge transfer into a modified Santus model, fatigue life predictions for all three microstructures in both air and corrosive environments show good agreement with experimental results.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"203 ","pages":"Article 109257"},"PeriodicalIF":6.8,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145021019","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":"Fatigue behaviour of PEEK fabricated by material extrusion additive manufacturing","authors":"Hasan Alhashmi , S. Kumar","doi":"10.1016/j.ijfatigue.2025.109262","DOIUrl":"10.1016/j.ijfatigue.2025.109262","url":null,"abstract":"<div><div>This study investigates the fatigue behaviour of polyether ether ketone (PEEK) fabricated via material extrusion additive manufacturing—specifically fused filament fabrication (FFF)—with an emphasis on the interactions between stress, frequency, and temperature. Tensile tests conducted across varying strain rates and temperatures reveal that increasing strain rate enhances tensile strength and Young’s modulus but reduces elongation, whereas increasing temperature lowers tensile strength and stiffness while increasing elongation. Guided by these insights, fatigue tests were performed under cyclic tension–tension loading with a stress ratio of 0.5 at a fixed frequency of 5 Hz to establish a stress–life (S–N) curve. Specimens sustained up to 1 million cycles at 75 MPa (88.3 % of tensile strength), with fatigue life decreasing at higher stress amplitudes. Additional tests at varying frequencies and temperatures further demonstrated reductions in fatigue life at higher frequency and elevated temperature. Compared to moulded PEEK, the fatigue performance of FFF-printed PEEK is degraded by process-induced defects that promote viscoelastic losses, interlayer plasticity, and self-heating, accelerating damage and failure. Fractography using scanning electron microscopy (SEM) revealed a combination of brittle and ductile failure modes, while micro-computed tomography (µCT) enabled visualization of inter-bead delamination within the printed microstructure. These results establish quantitative links between processing, microstructure, and fatigue life in 3D-printed PEEK, providing a foundation for component design and qualification in cyclically loaded, high-performance applications.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"203 ","pages":"Article 109262"},"PeriodicalIF":6.8,"publicationDate":"2025-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217844","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":"Two-stage fatigue crack detection framework with crack-preserving downsampler","authors":"Andrii Kompanets , Remco Duits , Davide Leonetti , H.H. (Bert) Snijder","doi":"10.1016/j.ijfatigue.2025.109179","DOIUrl":"10.1016/j.ijfatigue.2025.109179","url":null,"abstract":"<div><div>Inspection of steel bridges is essential for maintaining structural integrity and ensuring public safety. Automation of such inspections using neural networks for the visual detection of fatigue cracks is a prominent way to improve structural reliability and operational efficiency. This is often done using multiple neural networks to ensure the reliability of the results. Therefore, in this work, a two-stage crack detection and sizing framework for images of steel bridges is proposed and analysed in detail, which combines two neural networks. Additionally, it is shown that standard image downsampling methods can be non-optimal for the crack detection task because of the small width of the cracks at the surface. Hence, image downsampling is an important step for automatic crack detection. This is applied to the images contained in the Cracks in Steel Bridges (CSB) dataset In this work, a crack-preserving downsampling method is introduced, which is designed to downsample images in such a way that (our two-stage) crack detection in images of steel bridges shows higher performance.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"203 ","pages":"Article 109179"},"PeriodicalIF":6.8,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145011113","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":"Role of interfacial interaction in the temperature-dependent fatigue behavior of Cr-coated Zr-4 alloy","authors":"Hailin Zhai, Xianfeng Ma, Wenjie Zhang, Xuening Si, Ziyi Li, Jishen Jiang, Huanyue Lin","doi":"10.1016/j.ijfatigue.2025.109260","DOIUrl":"10.1016/j.ijfatigue.2025.109260","url":null,"abstract":"<div><div>This study systematically investigates the temperature-dependent fatigue mechanisms of Cr-coated Zr-4 alloy, focusing on interfacial interactions under cyclic loadings. At 25 °C, channel cracks occurred in the brittle Cr coating, propagating into the Zr-4 substrate and inducing localized stress concentrations at the interface that accelerated fatigue failure. In contrast, at 400 °C, the Cr coating exhibited remarkable ductility, suppressing substrate plastic deformation and crack initiation at the interface. Crystal plasticity simulations demonstrated that the Cr coating reduced accumulated energy dissipation in the interfacial region at 400 °C, delaying crack nucleation. A critical discovery was the formation of a 300–500 nm-thick nanocrystalline Zr layer at the interface, triggered by dynamic recrystallization during cyclic loading. This layer featured refined grains (∼100 nm), which mitigated dislocation accumulation, redistributed strain, and enhanced interfacial cohesion. Furthermore, the presence of {<span><math><mrow><mn>10</mn><mover><mrow><mn>1</mn></mrow><mrow><mo>¯</mo></mrow></mover><mn>2</mn></mrow></math></span>} deformation twins within the nanocrystals synergized with slip, expanding the pathways for plastic deformation and consequently enhancing the plastic deformability of the nanocrystalline layer. The interplay of Cr coating ductility, grain morphology transition (columnar-to-equiaxed), and interfacial nano-crystallization synergistically improved fatigue resistance at 400 °C. These findings underscore the critical role of temperature-modulated interfacial deformation mechanisms in governing fatigue performance, providing a foundation for optimizing Cr-coated Zr-4 alloys in high-temperature nuclear applications.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"203 ","pages":"Article 109260"},"PeriodicalIF":6.8,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047312","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":"Corrigendum to “Fatigue crack growth retardation due to crack closure in high-strength steel under high-pressure hydrogen”. [Int. J. Fatig. 202 (2026) 109235]","authors":"Aman Arora , Akinobu Shibata , Hisao Matsunaga","doi":"10.1016/j.ijfatigue.2025.109254","DOIUrl":"10.1016/j.ijfatigue.2025.109254","url":null,"abstract":"","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"202 ","pages":"Article 109254"},"PeriodicalIF":6.8,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145026878","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}
Sheng-xuan Diao , Jin-yong Xiao , Yong-bao Chen , Fang Liu , Jie Yang
{"title":"Cluster-guided cGAN-based prediction of whole fatigue crack propagation process across diverse metallic materials","authors":"Sheng-xuan Diao , Jin-yong Xiao , Yong-bao Chen , Fang Liu , Jie Yang","doi":"10.1016/j.ijfatigue.2025.109258","DOIUrl":"10.1016/j.ijfatigue.2025.109258","url":null,"abstract":"<div><div>Conventional fatigue crack propagation models face notable challenges in feature dimensionality coverage, scale adaptability, and data scarcity. To address the challenge that existing methods frequently show limited generalization when applied to diverse metallic materials, this study proposes a novel prediction framework—cGAN data augmentation-based deep neural network (cGAN-DA-Net)—that aims to improve the accuracy and robustness of fatigue crack propagation prediction across diverse metallic materials. K-means clustering is first used to guide the data generation process of the cGAN, and the resulting synthetic data are compared with those generated by a traditional GAN. The results show that the cGAN-generated fatigue crack propagation data exhibit superior agreement with real experimental data. The enhanced data are then used to train and evaluate multiple models, including conventional data-driven algorithms (random forest, support vector regression, and K-nearest neighbors), their data-augmented counterparts, and the proposed cGAN-DA-Net model. The findings reveal that while data augmentation improves the performance of conventional models, substantial prediction errors still remain. In contrast, the cGAN-DA-Net model achieves the highest prediction accuracy across different crack scales, maintaining all predictions within a ± 2.5 × error band. These results demonstrate that the proposed cGAN-DA-Net model provides a more accurate and robust approach for predicting whole fatigue crack propagation process across diverse metallic materials. Finally, SHapley Additive exPlanations (SHAP) analysis is employed to interpret the model and identify dominant features, including cycle number, applied load, testing temperature, tensile strength, and key alloying elements (e.g., Cu, C, and Si), thereby confirming the physical consistency and feature integration capability of the model.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"203 ","pages":"Article 109258"},"PeriodicalIF":6.8,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145009092","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":"Unifying the crystal plasticity, neuber/glinka and elastic follow-up frameworks to evaluate creep-fatigue in gas turbine single crystal nickel superalloys","authors":"Christos Skamniotis","doi":"10.1016/j.ijfatigue.2025.109249","DOIUrl":"10.1016/j.ijfatigue.2025.109249","url":null,"abstract":"<div><div>A local strain method is developed to estimate creep-fatigue life at hot spots based on linear elastic FE analysis. The method combines the concepts of Crystal Plasticity, Neuber/Glinka and elastic follow-up factor and predicts cyclic plastic-creep deformation at the hole of a Nickel-based single crystal plate under temperature cycling between 20 °C and 1100 °C. The results agree with Crystal Plasticity Finite Element (CPFE) simulations and indicate that: (a) Neuber/Glinka rules apply to single crystal cubic metals, (b) the increase of Young’s modulus on shutdown drives excessive residual stresses and low cycle fatigue, (c) the elastic follow-up factor <span><math><mi>Z</mi></math></span> increases during non-local creep at high temperature, but room temperature plasticity on unloading resets <span><math><mi>Z</mi></math></span> to low values. The competition between hot creep and cold plasticity controls whether local strain-ratchetting occurs in compressive or the tensile direction and cannot be captured by Neuber/Glinka rules alone. However, the combination of Glinka and Neuber suffices to predict reasonably well the cyclic strain range related to low cycle fatigue. These results extend the understanding of fatigue-creep-ratchetting failure to leverage industrial/academic research on the structural integrity of high temperature technologies, including fusion/fission reactors, hydrogen gas turbines, re-usable space vehicles.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"202 ","pages":"Article 109249"},"PeriodicalIF":6.8,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144988273","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":"Fatigue crack initiation and propagation behaviour of 316L under strain-controlled mode considering the interaction of crack closure and compressive load effect","authors":"Xinghui Chen, Wei Zhang, Runyang Ma, Qiaofa Yang, Fei Liang, Le Chang, Changyu Zhou","doi":"10.1016/j.ijfatigue.2025.109259","DOIUrl":"10.1016/j.ijfatigue.2025.109259","url":null,"abstract":"<div><div>This work investigates the fatigue crack initiation and propagation behaviour of 316L stainless steel under negative strain ratios. Crack driving force parameters based on different fracture criteria are comparatively discussed. The cyclic deformation response at crack tip region is characterized using digital image correlation (DIC) and electron backscatter diffraction (EBSD). Results show that crack initiation is significantly affected by the variation in notch stress concentration under tensile loads, and the introduction of compressive loads contributes to strain localization. Concentrated strain gradients and de-twinning process under interference of high-density dislocations induce crack initiation. In addition to the primary driving influence of tensile loads, the increasing crack closure level inhibits crack driving force provided by compressive load effect. Moreover, it is observed that the expansion of the residual tensile plastic zone is further inhibited by the plastic wake zone due to the significant crack closure behaviour. Finally, a crack growth rate model is proposed by considering the strain ratio effect and the influence of crack tip plastic zone based on the interaction of crack closure and compressive load effect. It is found that the proposed model is robust in predicting the crack growth rate at both crack initiation and propagations stages.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"202 ","pages":"Article 109259"},"PeriodicalIF":6.8,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144996774","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}
Guang-jun Zeng , Jin-feng Li , Zhen-zhen Liu , Tian-le Liu , Hua Zhou , Bao Qi , Yi-ming Guo , Tian-yu Peng , Peng-cheng Ma , Yong-lai Chen
{"title":"Different fatigue crack propagation resistance anisotropy of Al-Li alloy cold-rolled sheet and hot-rolled plate","authors":"Guang-jun Zeng , Jin-feng Li , Zhen-zhen Liu , Tian-le Liu , Hua Zhou , Bao Qi , Yi-ming Guo , Tian-yu Peng , Peng-cheng Ma , Yong-lai Chen","doi":"10.1016/j.ijfatigue.2025.109256","DOIUrl":"10.1016/j.ijfatigue.2025.109256","url":null,"abstract":"<div><div>The fatigue crack propagation (FCP) resistance anisotropy of Al-Li alloy cold-rolled (CR) sheets and hot-rolled (HR) plates was systematically investigated through the integrated microstructural and crystallographic analysis. By employing the equivalent slip system number (<em>ESSN</em>) as a novel metric to quantify crack path tortuosity and slip activity. It was revealed that the T8-aged CR and HR samples showed higher strength along rolling direction (RD) due to their higher crystallographic orientation factor. Notably, the <em>ESSN</em> value of T8-aged CR sample along the transverse-longitudinal (TL) direction was higher than that of the longitudinal–transverse (LT) direction, which facilitated readily activation of slip systems within grains for transgranular crack propagation in CR-TL sample. Consequently, the CR-TL samples presented more tortuous crack paths with pronounced crack branching and enhanced FCP resistance compared to CR-LT samples. In contrast, the HR-LT sample demonstrated superior FCP resistance compared to HR-TL, CR-TL and CR-LT samples, which was primarily related to the blocking effect at grain boundaries and sub-grain zones. The sub-grain zones promoted microcrack formation, while the finer T<sub>1</sub> precipitates within the sub-grain zones were more susceptible to multi-step sheared by dislocations, collectively contributing to the enhanced FCP resistance in HR-LT samples.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"202 ","pages":"Article 109256"},"PeriodicalIF":6.8,"publicationDate":"2025-08-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144920284","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}
Long Jin , Yu-Ke Liu , Ming-Liang Zhu , Shang-Lin Zhang , Min Yang , Tian-Da Yu , Fu-Zhen Xuan
{"title":"Extension of low cycle fatigue life model to thermal aging for 20000 h of a low alloy steel","authors":"Long Jin , Yu-Ke Liu , Ming-Liang Zhu , Shang-Lin Zhang , Min Yang , Tian-Da Yu , Fu-Zhen Xuan","doi":"10.1016/j.ijfatigue.2025.109255","DOIUrl":"10.1016/j.ijfatigue.2025.109255","url":null,"abstract":"<div><div>Axial low cycle fatigue tests were performed on the thermal aged low alloy steels (LASs). The fatigue life declined after thermal aging for 20000 h, characterized by diminished plastic strain amplitude, enhanced cyclic hardening, and reduced ductility. Post-fatigue fractography of the material after thermal aging revealed elevated dislocation density, dense dislocation pile-ups and tangles, which compromised carbide’s ability to block cracks and degraded the bainite phase, and further accelerated crack initiation and propagation. A previously established fatigue model based on the thermal aging parameter was extended to 20000 h and demonstrated sound applicability. Moreover, this model was embedded in a Physics-Informed Neural Network (PINN) framework to enhance the accuracy of fatigue life prediction. This study provides both data and guidance for LAS fatigue design in extended service applications.</div></div>","PeriodicalId":14112,"journal":{"name":"International Journal of Fatigue","volume":"202 ","pages":"Article 109255"},"PeriodicalIF":6.8,"publicationDate":"2025-08-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144912518","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}