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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: closed (20 April 2026) | Viewed by 13290

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Prof. Dr. Joel de Jesus

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Department of Mechanical Engineering, University of Coimbra, 3030-788 Coimbra, Portugal
Interests: structural integrity; fatigue; fracture; fatigue in corrosion environments; material characterization
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Dear Colleagues,

Given that fatigue and fracture phenomena account for 80% to 90% of failures in mechanical components, it is crucial to study these phenomena to ensure long-term durability and reliability. The introduction of new materials and manufacturing processes presents new challenges in terms of design, requiring more targeted research. This Special Issue aims to serve as a forum for analyzing new trends in fracture mechanics and fatigue design across all materials, with a particular focus on new materials, production processes, failure models, and design criteria. Papers addressing the effects of processing techniques, microstructural features, loading history, environmental conditions, and the modeling of mechanical behavior, as well as those covering advanced applications, are encouraged. Both experimental and numerical approaches will be considered. The Special Issue is open to both original research and review articles.

Prof. Dr. Joel De Jesus
Guest Editor

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Keywords

fatigue
fracture
fatigue crack growth
corrosion fatigue
low-cycle fatigue
high-cycle fatigue
numerical fatigue analysis
fatigue crack initiation
variable amplitude fatigue
fatigue damage accumulation
failure analysis
stress-based, strain-based, and energy-based criteria
linear elastic fracture mechanics
elasto-plastic fracture mechanics
computational fracture mechanics

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Published Papers (11 papers)

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Research

18 pages, 3077 KB

Open AccessArticle

Ratcheting Evaluation of SS304 Samples Undergoing Peak-Valley Loading Reversals with Hold Time Periods at Room Temperature Through the Incorporation of the Static Recovery Term

by Petar Jevtic and Ahmad Varvani-Farahani

Appl. Sci. 2026, 16(9), 4317; https://doi.org/10.3390/app16094317 - 28 Apr 2026

Viewed by 229

Abstract

The present study intends to evaluate the ratcheting of 304 stainless steel samples at room temperature, subjected to various loading spectra and holding times through the use of the combined Ahmadzadeh–Varvani (A-V) kinematic and Lee–Zavrel (L-Z) isotropic hardening rules. The nonlinear and time-dependent [...] Read more.

a_{r e c}

and

R_{r e c}

were implemented in the hardening framework to account for the static recovery terms (SRTs) in the kinematic and isotropic hardening descriptions. The static recovery phenomenon promoted ratcheting in steel samples tested under asymmetric loading cycles with holding time peak/valley events. The static recovery phenomenon accounts for the restoration process, elevating the plastic deformation and reducing the number of cycles to material failure. The framework with the SRT enabled the prediction of material ratcheting involving the loading rate and dwell time at room temperature. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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24 pages, 2557 KB

Open AccessArticle

Fatigue Assessment of Notched AM Scalmalloy Incorporating Surface Roughness in an Energy-Based Framework

by Sabrina Vantadori, Camilla Ronchei, Andrea Zanichelli and Daniela Scorza

Appl. Sci. 2026, 16(6), 2895; https://doi.org/10.3390/app16062895 - 17 Mar 2026

Viewed by 275

Abstract

In engineering practice, additively manufactured (AM) metal and metal alloy structural components, which often contain geometric discontinuities to fulfil functional requirements, are subjected to cyclic service loads. Among the possible loading configurations, far-field Mode I loading is frequently considered as a nominal reference condition. Within this context, a methodology for the fatigue assessment of notched AM Scalmalloy components subjected to Mode I far-field loading is proposed, combining the Strain Energy Density (SED) approach with a multiaxial critical plane-based fatigue criterion. The fatigue assessment is carried out at a verification point whose position is defined as a function of the characteristic length of the SED control volume for Mode I loading, determined through two alternative procedures, and of the surface roughness of the component. The proposed methodology is validated against experimental fatigue data available in the literature for AM Scalmalloy specimens featuring a circumferential semi-circular notch and subjected to Mode I far-field cyclic loading, which induces a locally multiaxial stress state at the notch root, given that the formulation does not rely on material-specific assumptions and could in principle be extended to other notched AM metal and metal alloy components. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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16 pages, 9682 KB

Open AccessArticle

Quasi-Static and Fatigue Strength of Copper-Brazed Stainless Steel

by Srečko Glodež, Tonica Bončina, Žan Dvoršak, Branko Nečemer and Franc Zupanič

Appl. Sci. 2026, 16(4), 2160; https://doi.org/10.3390/app16042160 - 23 Feb 2026

Viewed by 562

Abstract

This study investigates the quasi-static and fatigue strength of copper-brazed 316L stainless steel. Quasi-static and fatigue tests were conducted at room temperature (20 °C) using a Zwick/Roell Vibrophore 100 testing machine and specially designed copper-brazed specimens. Two types of specimens were prepared—tensile and shear specimens—to obtain the stress–strain relationships (σ–ε and τ–ε) and the fatigue life (S–N) curves. Based on the experimental results, the quasi-static and fatigue strengths of the copper-brazed joints under external tensile and shear loading were evaluated. The fatigue tests reveal that the shear fatigue strength is significantly lower than the tensile fatigue strength. Furthermore, a comprehensive investigation was conducted, focusing on the metallographic characterisation of the brazed joint and fractographic analyses of fracture surfaces obtained under quasi-static and fatigue loading, with particular emphasis on the shear strength of the investigated brazed joint. The experimental results obtained may be crucial for designing engineering structures (e.g., plate heat exchangers), where copper-brazed joints are the weakest members of the structure. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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23 pages, 4514 KB

Open AccessArticle

Fitness-for-Service Analysis of the Interplay Between a Quarter-Circle Corner Crack and a Parallel Semi-Elliptical Surface Crack in a Semi-Infinite Solid Subjected to In-Plane Bending Part II—The Effect on the Semi-Elliptical Surface Crack

by Mordechai Perl, Cesar Levy and Qin Ma

Appl. Sci. 2026, 16(3), 1240; https://doi.org/10.3390/app16031240 - 26 Jan 2026

Viewed by 312

Abstract

The impact of a quarter-circle corner crack on an adjacent parallel semi-elliptical surface crack (SESC) located in a semi-infinite solid subjected to in-plane bending is studied using a 3-D finite element analysis. The stress intensity factor (SIF) distributions along the front of the SESC are evaluated to determine said impact. The SESC’s semi-major axis ranged from a₁ = 10 mm to 30 mm with ellipticities of b₁/a₁ varying from 0.1 to 1.0 for a constant quarter-circle corner crack length of a₂ = 15 mm. Furthermore, several crack configurations are considered where the normalized vertical and horizontal gaps between the two cracks are taken to be H/a₂ = 0.4 and 1.2 and S/a₂ = −0.5 and 1.0, respectively. The results show that the effect of the quarter-circle corner crack on the SESC can be considerable both in amplifying and in attenuating the SIFs along the semi-elliptical surface crack front. Moreover, these opposite effects can occur simultaneously, but in different sections of the SESC’s crack front. The magnitude and pattern of these effects depend on the length and ellipticity of the SESC. It is further concluded that when considering the fitness-for-service of a critical real mechanical component, a complete 3-D analysis is needed to provide a reliable solution for such crack configurations. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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27 pages, 60244 KB

Open AccessArticle

Tensile and Fatigue Performance of Cold-Work Tool Steels for Adjustable Forming Tools

by Kaarel Siimut, Kasper Mygind Madsen, Ermanno Ceron and Chris Valentin Nielsen

Appl. Sci. 2026, 16(2), 954; https://doi.org/10.3390/app16020954 - 16 Jan 2026

Viewed by 580

Abstract

Forming tools adjustable by tensile elastic deformations offer opportunities for improved process control and reduced wear in high-volume metal forming processes such as ironing. However, the lack of tensile and fatigue data for hardened cold-work tool steels limits their broader adoption. This study investigates the mechanical performance of three tool steels—Vanadis^®4 Extra SuperClean, Vancron^® SuperClean, and Caldie^®—through uniaxial tensile and fatigue testing, supplemented by destructive static and fatigue/wear tests on specimens representative of an adjustable ironing punch. Non-coated specimens exhibited ultimate tensile strengths above 2700 MPa with approximately 2% plastic strain, while coated specimens fractured in a brittle manner between 1600–1900 MPa. Fatigue life at stress ranges between 1450–1750 MPa varied from several thousand to over four million cycles, with crack initiation linked to non-metallic inclusions and precipitates 10–30 μm in size. Finite element simulations accurately linked failure observed in uniaxial tests to the component-level tests, confirming that first principal stress is a reliable predictor for punch failure. All punch specimens withstood 10⁶ cycles at diameter changes up to 140 μm (4‰), with coated punches exhibiting minimal wear and non-coated ones showing localized surface damage. The findings support material and coating selection for adjustable forming tools and highlight opportunities for further optimization. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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20 pages, 1961 KB

Open AccessArticle

Development and Evaluation of Frequency Sensitivity Models in Ultrasonic Fatigue Testing of Ferritic-Pearlitic Steels

by Lewis Milne, Yevgen Gorash and Tugrul Comlekci

Appl. Sci. 2026, 16(1), 105; https://doi.org/10.3390/app16010105 - 22 Dec 2025

Cited by 1 | Viewed by 649

Abstract

The increased test frequency inherent in Ultrasonic Fatigue Testing (UFT) is commonly observed to result in an increased fatigue resistance for ferritic, low-carbon steels. In this investigation, the fatigue response of S275J2 ferritic structural steel is evaluated at both 20 kHz and 50 Hz. At the ultrasonic frequency, an increase in the fatigue limit of 136 MPa and an increase in the finite life region of 150 MPa was observed, alongside a reduction in the slope of the S-N curve. By combining the S275J2 results with additional data from the literature, generalised versions of previously proposed frequency sensitivity models are produced by evaluating the model coefficients as a function of different combinations of the material properties. Additionally, a new frequency sensitivity model was proposed by evaluating the empirical change in the S-N curve coefficients as a function of these material properties. For all of the models, it was found that the best correlation was against the ferrite content divided by the tensile strength. The generalised forms of these models were rearranged to produce correction factors, which allow the conventional frequency fatigue response to be estimated based on the UFT test. The most reliable correction method was found to be using the empirical change in the S-N curve exponent. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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20 pages, 2435 KB

Open AccessArticle

Fitness-for-Service Analysis of the Interplay Between a Quarter-Circle Corner Crack and a Parallel Semi-Elliptical Surface Crack in a Semi-Infinite Solid Subjected to In-Plane Bending: Part I—The Effect on the Quarter-Circle Corner Crack

by Mordechai Perl, Qin Ma and Cesar Levy

Appl. Sci. 2025, 15(23), 12718; https://doi.org/10.3390/app152312718 - 1 Dec 2025

Cited by 1 | Viewed by 512

Abstract

For the purpose of Fitness-For-Service analysis, the effect of a semi-elliptical surface crack on a parallel quarter-circle corner crack in a semi-infinite solid subjected to pure bending is studied using 3D finite element analyses. While keeping the geometry of the quarter-circle corner crack constant, the SIF distributions along its front are studied for various geometrical configurations of the semi-elliptical surface crack and several crack layouts. The problem is solved for a wide range of parameters, e.g., the ellipticity of the semi-elliptical b₁/a₁ = 0.1~1; the relative crack size of the two parallel cracks a₁/a₂ = 1/3~2; the normalized vertical and horizontal gaps between the two cracks, H/a₂ = 0.4 and 1.2, and S/a₂ = −0.5 and 1, respectively. The results indicate that the semi-elliptical surface crack might have a considerable effect on the SIF distribution along the quarter-circle corner crack both in amplifying and reducing the SIF. These effects are highly dependent on the semi-elliptical surface crack geometry and the cracks’ configuration. It is further concluded that it is necessary to perform a full 3D analysis, similar to the present one, in order to quantify the “real” effect of neighbouring cracks, in view of the existing inadequate fitness for service criteria. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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22 pages, 11893 KB

Open AccessArticle

Integrated Fatigue Evaluation of As-Built WAAM Steel Through Experimental Testing and Finite Element Simulation

by Sanjay Gothivarekar, Steven Brain, Bart Raeymaekers and Reza Talemi

Appl. Sci. 2025, 15(20), 10936; https://doi.org/10.3390/app152010936 - 11 Oct 2025

Cited by 1 | Viewed by 1145

Abstract

Additive Manufacturing (AM) has attracted considerable interest over the past three decades, driven by growing industrial demand. Among metal AM techniques, Wire and Arc Additive Manufacturing (WAAM), a Directed Energy Deposition (DED) variant, has emerged as a prominent method for producing large-scale components with high deposition rates and cost efficiency. However, WAAM parts typically exhibit rough surface profiles, which can induce stress concentrations and promote fatigue crack initiation under cyclic loading. This study presents an integrated experimental and numerical investigation into the fatigue performance of as-built WAAM steel. Fatigue specimens extracted from a WAAM-fabricated wall were tested under cyclic loading, followed by fractography to assess the influence of surface irregularities and subsurface defects on fatigue behaviour. Surface topography analysis identified critical stress-concentration regions and key surface roughness parameters. Additionally, 3D scanning was used to reconstruct the specimen topography, enabling detailed 2D and 3D finite element (FE) modelling to analyze stress distribution along the as-built surface and predict fatigue life. A Smith-Watson-Topper (SWT) critical plane-based approach was applied for multiaxial fatigue life estimation. The results reveal a good correlation between experimental fatigue data and numerically predicted results, validating the proposed combined methodology for assessing durability of as-built WAAM components. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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20 pages, 27305 KB

Open AccessArticle

Additively Manufactured Inconel 718 Low-Cycle Fatigue Performance

by Joseph Johnson and Daniel Kujawski

Appl. Sci. 2025, 15(3), 1653; https://doi.org/10.3390/app15031653 - 6 Feb 2025

Cited by 2 | Viewed by 3435

Abstract

Inconel 718 is one of the most used alloys within the aerospace gas turbine industry. The acceptance of Inconel 718 within the aerospace gas turbine industry has largely been due to its high strength and fatigue capabilities up to 677 °C (1250 °F). This alloy is traditionally produced through conventional manufacturing methods, such as casting, wrought, and sheet forming. The various traditional manufacturing methods of this alloy have been well understood and characterized for use in critical components. However, Inconel 718 can also be produced with non-traditional manufacturing methods, such as by additive manufacturing. Producing Inconel 718 by additive manufacturing has the opportunity to design more complex components that provide distinct advantages over conventionally produced components. However, prior to implementing additively manufactured Inconel 718 within the aerospace gas turbine industry, there needs to be a complete understanding of the material’s performance. In an effort to completely characterize additively manufactured Inconel 718, this study focuses on the characterization of the alloy’s low-cycle fatigue performance. Specimens were produced via the laser powder bed fusion process in a vertical orientation. Both as-printed surfaces and fully machined surface specimens were evaluated at 24 °C (75 °F) and 538 °C (1000 °F). Fractography analysis was then completed on the specimens to understand differences in the crack initiation and propagation with respect to test temperatures and surface conditions. Based on these tests, it was shown that the fatigue life knockdown due to the as-printed surface conditions was 62.8% at 538 °C (1000 °F) versus only 8.5% at 24 °C (75 °F). These findings are discussed in detail within this article, and future work is proposed. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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17 pages, 9525 KB

Open AccessArticle

Assessment of Fatigue Life and Failure Criteria in Ultrasonic Testing Through Thermal Analyses

by Maria Clara Carvalho Teixeira, Marcos Venicius Soares Pereira, Rodrigo Fernandes Magalhães Souza, Felipe Rebelo Lopes and Talita Goulart da Silva

Appl. Sci. 2025, 15(3), 1076; https://doi.org/10.3390/app15031076 - 22 Jan 2025

Cited by 2 | Viewed by 1790

Abstract

An experimental study was conducted to analyze temperature evolution during very high cycle fatigue tests. The temperature–number of cycles (T–N) curve is typically divided into three phases: Phase I—a rapid temperature increases at the start of the test, Phase II—temperature stabilization, and Phase III—a sharp temperature rise at the test’s end, coinciding with specimen fracture. The high frequencies used in ultrasonic fatigue testing can induce self-heating in specimens, but the thermal effects are not yet fully understood. Temperature is known to influence the fatigue performance of materials. To explore this, specimens were subjected to varying stress levels and intermittent loading conditions while monitoring temperature evolution using infrared thermography. The T–N curves were obtained, and S–N curves were constructed for specimens tested at room temperature. All tests were performed under fully reversed loading conditions. The experimental data were used to evaluate models commonly applied in conventional fatigue testing. Additionally, the temperature gradient at the beginning of the ultrasonic fatigue test and the heat dissipation per cycle were estimated and analyzed as potential fatigue damage parameters. These findings indicate that parameters derived from the T–N curve have significant potential for predicting very high cycle fatigue life. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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13 pages, 3925 KB

Open AccessArticle

Influence of Low-Temperature Stress-Relieving Treatment in the Fatigue Life of Components Produced by Laser Powder Bed Fusion in AlSi10Mg

by Malcolm António, Rui Fernandes, Joel de Jesus, Luís Borrego, Ricardo Branco, José da Costa and José Ferreira

Appl. Sci. 2025, 15(1), 112; https://doi.org/10.3390/app15010112 - 27 Dec 2024

Cited by 2 | Viewed by 2030

Abstract

This study investigates the impact of low-temperature stress-relieving treatment on the fatigue life of AlSi10Mg components produced by Laser Powder Bed Fusion (L-PBF). The research focuses on a bicycle crank arm, comparing its performance in as-built and heat-treated conditions. The heat treatment involved stress-relieving at 250 °C for 2 h, followed by water quenching. The study found that the as-built condition exhibited a supersaturated Si cellular-dendritic microstructure, while the heat-treated condition showed coarsening of β-Mg₂Si phases and Si precipitates. This morphological change led to a decrease in hardness and an increase in ductility. Fatigue tests demonstrated that the heat-treated crank arms achieved the target of 100,000 cycles without failure, unlike the as-built samples, which failed prematurely. The fractography analysis identified surface porosity as the primary crack initiation site. The findings suggest that low-temperature stress-relieving treatment can enhance the fatigue performance of L-PBF AlSi10Mg components by reducing residual stresses and improving defect tolerance. Full article

(This article belongs to the Special Issue Fatigue and Fracture Behavior of Engineering Materials)

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