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Metals
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Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials
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Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (30 June 2023) | Viewed by 25097

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editors

Prof. Dr. Haitao Cui

E-Mail Website
Guest Editor
College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: fatigue; life prediction; optimal design; nonlinear damage; constitutive relationship; advanced alloys
Dr. Qinan Han

E-Mail Website
Guest Editor
College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: fatigue; damage mechanism; in situ testing; crystal plasticity simulation; life prediction; crack formation

Special Issue Information

Dear Colleagues,

Metals and alloys are widely used in engineering applications, often requiring careful consideration of complex loading conditions and usually limited by fatigue and fracture performance. The behaviour of metals and alloys under fatigue loading is a multi-scale, complex problem involving microscopic damage initiation, small crack formation, coalescence, propagation and eventually macroscopic fracture failure.

To study the fatigue of metallic materials, experimental, theoretical and numerical methods need to be developed. Novel testing and characterization techniques such as in situ observation, non-contact measurement and microscopic characterization provide insights into the fatigue process and damage mechanisms. Techniques for testing advanced fatigue life facilitate the generation of fatigue performance data. Fatigue and fracture theory, cyclic constitutive relationships, numerical simulations or data-driven methods enable the creation of accurate fatigue life prediction models, as well as optimal design for improved fatigue life.

In addition, fatigue is also affected by many factors, such as extreme conditions that involve multi-axis stress, high strain rates, and ultra-high/low temperatures, combined loads that involve thermal, mechanical and irradiation loadings,  microstructure heterogeneities such as defects, texture, crystal orientation, and grain morphology, to name a few. It is important to investigate metal fatigue under these conditions. With the development of novel techniques for manufacturing metallic materials, the relationship between processing, structure and fatigue property has also become an important topic.

This Special Issue aims to present recent research advancements regarding the fatigue of metallic materials. Potential topics may cover, but are not limited to, experimental testing, characterization, theory development and modelling of the fatigue behaviour of various metallic materials over different scales, with one or multiple physical processes. We also encourage the submission of research articles that integrate experimental or situational data with data-driven algorithms into the analysis of fatigue performance.

Prof. Dr. Haitao Cui
Dr. Qinan Han
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • fatigue
  • life prediction
  • damage mechanism
  • failure analysis
  • numerical simulation
  • cyclic constitutive relationship
  • optimal design
  • fatigue characterization
  • extreme conditions
  • crack behavior
  • data-driven method

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Published Papers (12 papers)

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Editorial

Jump to: Research, Review

3 pages, 165 KiB  
Editorial
Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials
by Haitao Cui and Qinan Han
Metals 2023, 13(10), 1752; https://doi.org/10.3390/met13101752 - 16 Oct 2023
Viewed by 1991
Abstract
Metallic materials are crucial in engineering applications and often subjected to complex loads and extreme environments, with fatigue being one of the key problems [...] Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)

Research

Jump to: Editorial, Review

19 pages, 12908 KiB  
Article
A Combined Numerical–Analytical Study for Notched Fatigue Crack Initiation Assessment in TRIP Steel: A Local Strain and a Fracture Mechanics Approach
by Peter I. Christodoulou and Alexis T. Kermanidis
Metals 2023, 13(10), 1652; https://doi.org/10.3390/met13101652 - 27 Sep 2023
Cited by 5 | Viewed by 1337
Abstract
In the fatigue design of metallic components using the safe-life approach, fatigue crack initiation as a development of slip systems at the nanoscale, followed by microstructurally short crack growth, is critical for the onset of structural failure. The development of reliable analytical tools [...] Read more.
In the fatigue design of metallic components using the safe-life approach, fatigue crack initiation as a development of slip systems at the nanoscale, followed by microstructurally short crack growth, is critical for the onset of structural failure. The development of reliable analytical tools for the prediction of crack initiation, although very complex due to the inherent multiscale fatigue damage processes involved, is important for promoting a more sophisticated design but, more importantly, enhancing the safety in regard to fatigue. The assessment of fatigue crack initiation life at the root of a V-shaped notch is performed by implementing a local strain and a fracture mechanics concept. In the low cycle fatigue analysis, the finite element method is used to determine the local stress–strain response at the notch root, which takes into account elastoplastic material behavior. Fatigue crack initiation is treated as the onset of a short corner crack by incremental damage accumulation and failure of a material element volume at the notch root. The finite element results are compared against established methodologies such as the Neuber and strain energy density methods. In the fracture mechanics approach, fatigue crack initiation is treated as the onset and propagation of a corner crack to a finite short crack. Fatigue experiments in two different transformation-induced plasticity (TRIP) steels were conducted to evaluate the analytical predictions and to determine the physical parameters for the definition of crack initiation. The analytical results show that the finite element method may be successfully implemented with existing fatigue models for a more accurate determination of the local stress–strain behavior at the notch tip in order to improve the assessment of fatigue crack initiation life compared to the established analytical methodologies. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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17 pages, 6051 KiB  
Article
Design for the Vent Holes of Gas Turbine Flow Guide Disks Based on the Shape Optimization Method
by Changlong Wen, Yanbing Zheng, Dong Mi, Zhengming Qian and Hongjian Zhang
Metals 2023, 13(7), 1151; https://doi.org/10.3390/met13071151 - 21 Jun 2023
Cited by 2 | Viewed by 1230
Abstract
Two shape optimization methods, based on non-parametric and geometric parameters, were developed to address stress concentrations in the vent holes of gas turbine flow guide disks. The design optimization focused on reducing the maximum equivalent stress at the hole edge in an aero-engine [...] Read more.
Two shape optimization methods, based on non-parametric and geometric parameters, were developed to address stress concentrations in the vent holes of gas turbine flow guide disks. The design optimization focused on reducing the maximum equivalent stress at the hole edge in an aero-engine gas turbine flow guide disk. The effectiveness of both methods in achieving this objective was studied. The results indicated that the non-parametric-based optimization method reduced the maximum equivalent stress at the hole edge by 24.5% compared to the initial design, while the geometric parameter-based optimization method achieved a reduction of 20.2%. Both shape optimization methods proved effective in reducing stress concentrations and improving fatigue life. However, the non-parametric shape optimization method resulted in a better design for the vent holes based on the study’s findings. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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16 pages, 5986 KiB  
Article
Mechanical Fracture of Aluminium Alloy (AA 2024-T4), Used in the Manufacture of a Bioproducts Plant
by Luis Fabian Urrego, Olimpo García-Beltrán, Nelson Arzola and Oscar Araque
Metals 2023, 13(6), 1134; https://doi.org/10.3390/met13061134 - 16 Jun 2023
Cited by 4 | Viewed by 1994
Abstract
Aluminium alloy (AA2024-T4) is a material commonly used in the aerospace industry, where it forms part of the fuselage of aircraft and spacecraft thanks to its good machinability and strength/weight ratio. These characteristics allowed it to be applied in the construction of the [...] Read more.
Aluminium alloy (AA2024-T4) is a material commonly used in the aerospace industry, where it forms part of the fuselage of aircraft and spacecraft thanks to its good machinability and strength/weight ratio. These characteristics allowed it to be applied in the construction of the structure of a pilot plant to produce biological extracts and nano-encapsulated bioproducts for the phytosanitary control of diseases associated with microorganisms in crops of Theobroma cacao L. (Cacao). The mechanical design of the bolted support joints for this structure implies knowing the performance under fatigue conditions of the AA2024-T4 material since the use of bolts entails the placement of circular stress concentrators in the AA2024-T4 sheet. The geometric correction constant (Y) is a dimensionless numerical scalar used to correct the stress intensity factor (SIF) at the crack tip during propagation. This factor allows the stress concentration to be modified as a function of the specimen dimensions. In this work, four compact tension specimens were modeled in AA2024-T4, and each one was modified by introducing a second circular stress concentrator varying its size between 15 mm, 20 mm, 25 mm, and 30 mm, respectively. Applying a cyclic load of 1000N, a load ratio R=-1 and a computational model with tetrahedral elements, it was determined that the highest SIF corresponds to the specimen with a 30 mm concentrator with a value close to 460 MPa.mm0.5. Where the crack propagation had a maximum length of 53 mm. Using these simulation data, it was possible to process each one and obtain a mathematical model that calculates the geometric correction constant (Y). The calculated data using the new model was shown to have a direct relationship with the behavior obtained from the simulation. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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16 pages, 5198 KiB  
Article
Change in the Properties of Rail Steels during Operation and Reutilization of Rails
by Kassym Yelemessov, Dinara Baskanbayeva, Nikita V. Martyushev, Vadim Y. Skeeba, Valeriy E. Gozbenko and Antonina I. Karlina
Metals 2023, 13(6), 1043; https://doi.org/10.3390/met13061043 - 30 May 2023
Cited by 18 | Viewed by 1590
Abstract
The paper considers the possibility of reusing previously used railway rails. The analysis is conducted using the standards and operating conditions of the rails of one of the Central Asian states, Kazakhstan, as an example. The operation of these rails causes significant stresses, [...] Read more.
The paper considers the possibility of reusing previously used railway rails. The analysis is conducted using the standards and operating conditions of the rails of one of the Central Asian states, Kazakhstan, as an example. The operation of these rails causes significant stresses, while the surface layers are strengthened as a result of cold hammering. These phenomena significantly change the physical and mechanical characteristics of rails. As a result, they may not be suitable in terms of parameters for basic use but can be suitable for installation on other tracks. The conducted studies have shown that when the standard service life of the RP65 rail expires, the surface layer is deformed to a depth of up to 300 microns, hardness increases, and internal residual stresses are formed. These changes lead to an increase in the strength properties of the rails. However, at the same time, cracks originate in the surface layer of the rail, thus worsening operational characteristics. The RP65 rails are used under a cyclic load of 700 kN (which is determined by the national standard), withstanding 790,000 cycles. When the load is reduced to 510 kN, these rails can withstand the 2,000,000 cycles required by the standard without failure. Thus, these rails can be reutilized only on non-loaded and non-critical sections. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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19 pages, 10857 KiB  
Article
Fatigue Crack Growth Behavior and Failure Mechanism of Nickel-Based Alloy GH4169 under Biaxial Load Based on Fatigue Test of Cruciform Specimen
by Zhirong Wu, Ying Pan, Hang Lei, Shuaiqiang Wang and Lei Fang
Metals 2023, 13(3), 588; https://doi.org/10.3390/met13030588 - 14 Mar 2023
Cited by 1 | Viewed by 1604
Abstract
Due to the complex geometry and various cyclic loads, aeroengine components are often in a multiaxial complex stress state during service. Multiaxial fatigue is a major cause of many air accidents. It is of great significance to study the fatigue failure mechanism of [...] Read more.
Due to the complex geometry and various cyclic loads, aeroengine components are often in a multiaxial complex stress state during service. Multiaxial fatigue is a major cause of many air accidents. It is of great significance to study the fatigue failure mechanism of aeronautical materials. This paper carries out biaxial fatigue tests on cruciform specimens and uses the surface replication method to record the initiation and propagation process of crack. Based on these fatigue tests, this paper studies the multiaxial fatigue characteristics of nickel-based alloy GH4169 for aeroengines and analyzes the fatigue crack growth behavior and failure mechanism of nickel-based alloys under a complex multiaxial stress state. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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21 pages, 6376 KiB  
Article
A 3D Polycrystalline Plasticity Model for Isotropic Linear Evolution of Intragranular Misorientation with Mesoscopic Plastic Strain in Stretched or Cyclically Deformed Metals
by Shao-Shi Rui, Yue Su, Jia-Min Zhao, Zhi-Hao Shang and Hui-Ji Shi
Metals 2022, 12(12), 2159; https://doi.org/10.3390/met12122159 - 15 Dec 2022
Cited by 1 | Viewed by 1678
Abstract
Two-dimensional electron back-scattered diffraction (2D-EBSD) mapping has been widely used for indicating the polycrystalline plasticity through intragranular misorientation parameters KAM and GROD, based on the empirically linear relationship between their average values and the mesoscopic plastic strain, in both stretched and cyclically [...] Read more.
Two-dimensional electron back-scattered diffraction (2D-EBSD) mapping has been widely used for indicating the polycrystalline plasticity through intragranular misorientation parameters KAM and GROD, based on the empirically linear relationship between their average values and the mesoscopic plastic strain, in both stretched and cyclically deformed metals. However, whether the intragranular misorientation measured on the 2D-EBSD observational plane objectively reflects the 3D polycrystalline plasticity or not is a rarely reported issue. In this research, we firstly compared the KAM and GROD values measured on 2D-EBSD observational planes with different angles to loading axis of a specimen in both undeformed clamp sections and deformed gauge section, to verify whether their average values increase isotropically or not with mesoscopic plastic strain. Then, we proposed six fundamental assumptions and developed a modified 3D polycrystalline plasticity model based on the 2D polycrystalline plasticity model in our previous work. This 3D polycrystalline plasticity model can explain the isotropic linear evolution of intragranular misorientation in deformed low alloy steel with uniform equiaxial grains. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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16 pages, 7705 KiB  
Article
Non-Unified Constitutive Models for the Simulation of the Asymmetrical Cyclic Behavior of GH4169 at Elevated Temperatures
by Xuteng Hu, Shuying Zhuang, Haodong Zheng, Zuopeng Zhao and Xu Jia
Metals 2022, 12(11), 1868; https://doi.org/10.3390/met12111868 - 2 Nov 2022
Cited by 2 | Viewed by 1515
Abstract
The tensile, creep, fatigue and creep-fatigue tests of the nickel-based superalloy GH4169 were carried out. According to the deformation characteristics of GH4169 alloy, the Ohno-Karim kinematic model (O-K model) can be used to describe the tensile behavior. The creep constitutive model presented in [...] Read more.
The tensile, creep, fatigue and creep-fatigue tests of the nickel-based superalloy GH4169 were carried out. According to the deformation characteristics of GH4169 alloy, the Ohno-Karim kinematic model (O-K model) can be used to describe the tensile behavior. The creep constitutive model presented in this paper can be used to predict the three-stage creep characteristics of the GH4169 alloy. The modified Ohno-Karim kinematic hardening model, combined with an isotropic hardening model, can well predict the cyclic softening behavior of the material under symmetric loads and the mean stress relaxation behavior under asymmetric loads. Based on the modified Ohno-Karim kinematic hardening model, isotropic hardening model and creep constitutive model, a non-unified constitutive model was established. The creep-fatigue behavior of the GH4169 alloy under symmetric and asymmetric loads is simulated by using the non-unified constitutive model. The simulation results are very close to the experimental results; however, the prediction results of the time-dependent relaxation load are relatively small. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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27 pages, 14994 KiB  
Article
Fatigue Reliability Prediction Method of Large Aviation Planetary System Based on Hierarchical Finite Element
by Ming Li, Yuan Luo and Liyang Xie
Metals 2022, 12(11), 1785; https://doi.org/10.3390/met12111785 - 23 Oct 2022
Cited by 5 | Viewed by 1826
Abstract
The reliability of planetary equipment determines the economic affordability and service safety, to a large extent, for a helicopter transmission system. However, with the continuous improvement of the progressiveness and large-scale degree of new aviation planetary equipment, the contradiction between reliability design indexes [...] Read more.
The reliability of planetary equipment determines the economic affordability and service safety, to a large extent, for a helicopter transmission system. However, with the continuous improvement of the progressiveness and large-scale degree of new aviation planetary equipment, the contradiction between reliability design indexes and R&D economy is also gradually highlighted. This paper takes the large aviation planetary system as a research object, aims to accurately evaluate the system reliability level formed in design processes, and deeply excavates the inherent characteristics of the planetary system in functional realization and builds a system fatigue reliability evaluation model accordingly. An advanced hierarchical finite element technology is used to calculate dangerous tooth load histories under the influence of system global elastic behavior, and the tooth probability fatigue strength is obtained through the gear low-cycle fatigue test and life distribution transformation method, so as to provide economic load and strength input variables, respectively, for the reliability model. This prediction method can provide targeted structural optimization guidance in the development and design of the large aviation planetary system and significantly reduce the cost of reliability index realization for this kind of large-scale, high-end equipment in design iteration processes. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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15 pages, 5977 KiB  
Article
Estimation Method of Relative Slip in Fretting Fatigue Contact by Digital Image Correlation
by Yue Su, Shao-Shi Rui, Qi-Nan Han, Zhi-Hao Shang, Li-Sha Niu, Hao Li, Hiroshi Ishikawa and Hui-Ji Shi
Metals 2022, 12(7), 1124; https://doi.org/10.3390/met12071124 - 30 Jun 2022
Cited by 4 | Viewed by 1997
Abstract
An experimental method that can quantify relative slip was developed using digital image correlation (DIC) in order to evaluate the sliding portion. The bridge-type test setup was designed to establish the fretting contact condition. The relative displacements between the contact surfaces were determined [...] Read more.
An experimental method that can quantify relative slip was developed using digital image correlation (DIC) in order to evaluate the sliding portion. The bridge-type test setup was designed to establish the fretting contact condition. The relative displacements between the contact surfaces were determined by DIC methods. Based on the evolution and distribution of relative slip, the transitions from gross slip to partial slip on the contact surface were found throughout all tests. This result indicated that the fretting scar was closely correlated to relative slip. The variation of relative slip corresponding to the stick-slip state was consistent with the tangential force coefficient. Besides, the load amplitude was an important factor for fretting fatigue damage, which can affect the stick-slip state. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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10 pages, 3529 KiB  
Article
Actual Marine Atmospheric Pre-Corrosion Fatigue Performance of 7075-T73 Aluminum Alloy
by Laixin Shi, Lin Xiang, Jianquan Tao, Qiang Chen, Jun Liu and Yong Zhong
Metals 2022, 12(5), 874; https://doi.org/10.3390/met12050874 - 21 May 2022
Cited by 8 | Viewed by 2103
Abstract
Actual marine atmospheric pre-corrosion behavior and its effect on the fatigue performance of 7075-T73 aluminum alloy were studied by means of marine atmospheric outdoor exposure testing and fatigue testing. The surface and cross-sectional microstructures of aluminum alloy specimens after different numbers of days [...] Read more.
Actual marine atmospheric pre-corrosion behavior and its effect on the fatigue performance of 7075-T73 aluminum alloy were studied by means of marine atmospheric outdoor exposure testing and fatigue testing. The surface and cross-sectional microstructures of aluminum alloy specimens after different numbers of days of exposure were analyzed. Localized pitting, and intergranular and exfoliation corrosion occurred during the outdoor exposure of aluminum alloy specimens in a marine atmosphere. The degree of severity of atmospheric corrosion increased with increasing duration of exposure. The effects of Fe-rich constituent particles (Al23CuFe4) and grain boundary precipitates (MgZn2) on the marine atmospheric corrosion behavior were discussed. In addition, when the exposure time was increased from 0 days to 15 days, the average fatigue life of aluminum alloy specimens decreased dramatically from about 125.16 × 104 cycles to 16.58 × 104 cycles. As the exposure time was further increased to 180 days, the average fatigue life slowly decreased to about 6.21 × 104 cycles. The fatigue fracture characteristics and the effect mechanism of marine atmospheric pre-corrosion on the fatigue life of 7075-T73 aluminum alloy were also analyzed. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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Review

Jump to: Editorial, Research

16 pages, 5655 KiB  
Review
Applications of Phase Field Methods in Modeling Fatigue Fracture and Performance Improvement Strategies: A Review
by Haitao Cui, Chenyu Du and Hongjian Zhang
Metals 2023, 13(4), 714; https://doi.org/10.3390/met13040714 - 5 Apr 2023
Cited by 7 | Viewed by 4217
Abstract
Fatigue fracture simulation based on phase field methods is a promising numerical approach. As a typical continuum approach, phase field methods can naturally simulate complex fatigue fracture behavior. Moreover, the cracking is a natural result of the simulation without additional fracture criterion. This [...] Read more.
Fatigue fracture simulation based on phase field methods is a promising numerical approach. As a typical continuum approach, phase field methods can naturally simulate complex fatigue fracture behavior. Moreover, the cracking is a natural result of the simulation without additional fracture criterion. This study first introduced the phase field fracture principle, then reviewed some recent advances in phase field methods for fatigue fracture modeling, and gave representative examples in macroscale, microscale, and multiscale structural simulations. In addition, some strategies to improve the performance of phase field models were summarized from different perspectives. The applications of phase field methods to fatigue failure demonstrate the ability to handle complex fracture behaviors under multiple loading forms and their interactions, and the methods have great potential for development. Finally, an outlook was made in four aspects: loading form, fatigue degradation criterion, coupled crystal plasticity, and performance improvement. Full article
(This article belongs to the Special Issue Fatigue Damage Mechanism and Fatigue Life Prediction of Metallic Materials)
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