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Metals
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Fatigue Assessment of Metals
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Fatigue Assessment of Metals

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

Deadline for manuscript submissions: closed (20 April 2025) | Viewed by 5512

Special Issue Editor

Prof. Dr. Guoqin Sun

E-Mail Website
Guest Editor
Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China
Interests: fatigue assessment; failure analysis; damage mechanics; fatigue modeling
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

You are invited to contribute to this upcoming Special Issue of Metals, entitled “Fatigue Assessment of Metals”. This issue will compile articles on theoretical and experimental research progress into metal crack initiation, crack propagation, and life estimation, with potential topics ranging from damage mechanism to life evaluation of metal materials and structures.

Fatigue damage is a typical form of metal component damage, and the fatigue damage of structural components often brings disastrous consequences. Preventing the accidental failure of structural components is one of the design objectives of any engineering structure. Based on fatigue tests and the simulation of metal components, the theory and method of fatigue damage assessments of metal materials or components are proposed. These methods promise to provides a bases for structural safety, as well as for the design, material selection, and process selection of metal components, so as to further improve the fatigue resistance of structures and delay or avoid fatigue failure. This work requires the participation of multidisciplinary expertise, including material science, structural analysis, detection technology, structural design, manufacturing technology, computer technology, quality assessment, physics, reliability, etc. In order to solve the complex engineering fatigue problem, it is necessary to involve both micro- and macro-scale theory and experimental methods.

A diverse variety of topics may be addressed under the umbrella of the fatigue assessment of metal materials and structures, including:

(1) Residual strength or life, including the influence of multi-site fatigue damage;

(2) Crack propagation, including the influence of multiple cracks or fatigue damage of multiple parts;

(3) Damage assessment using different fatigue damage detection;

(4) Life prediction includes crack initiation and crack propagation;

(5) Uniaxial and multiaxial fatigue damage assessments of different metal materials and structures;

and various related topics.

We look forward to your contributions to this Special Issue.

Prof. Dr. Guoqin Sun
Guest Editor

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 assement
  • strength assessment
  • life prediction
  • crack initiation
  • crack propagation
  • fatigue damage evaluation
  • fatigue modeling
  • fatigue damage mechanism
  • damage detection
  • fatigue failure

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Published Papers (6 papers)

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Research

26 pages, 5303 KiB  
Article
Machine Learning-Based Prediction of Fatigue Fracture Locations in 7075-T651 Aluminum Alloy Friction Stir Welded Joints
by Guangming Mi, Guoqin Sun, Shuai Yang, Xiaodong Liu, Shujun Chen and Wei Kang
Metals 2025, 15(5), 569; https://doi.org/10.3390/met15050569 - 21 May 2025
Viewed by 34
Abstract
Friction stir welding (FSW) is a solid-state joining technique widely used for aluminum alloys in aerospace, automotive, and shipbuilding applications, yet the prediction of fatigue fracture locations within FSW joints remains challenging for structural-life assessment. In this study, we investigate fatigue fracture location [...] Read more.
Friction stir welding (FSW) is a solid-state joining technique widely used for aluminum alloys in aerospace, automotive, and shipbuilding applications, yet the prediction of fatigue fracture locations within FSW joints remains challenging for structural-life assessment. In this study, we investigate fatigue fracture location prediction in 7075-T651 aluminum alloy FSW joints by applying four machine learning methods—decision tree, logistic regression, a three-layer back-propagation artificial neural network (BP ANN), and a novel Quadratic Classification Neural Network (QCNN)—using maximum stress, stress amplitude, and stress ratio as input features. Evaluated on an experimental test set of eight loading conditions, the QCNN achieved the highest accuracy of 87.5%, outperforming BP ANN (75%), logistic regression (50%), and decision tree (37.5%). Building on QCNN outputs and incorporating relevant material property parameters, we derive a Regional Fracture Prediction Formula (RFPF) based on a Fourier-series quadratic expansion, enabling the rapid estimation of fracture zones under varying loads. These results demonstrate the QCNN’s superior predictive capability and the practical utility of the RFPF framework for the fatigue failure analysis and service-life assessment of FSW structures. Full article
(This article belongs to the Special Issue Fatigue Assessment of Metals)
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12 pages, 11545 KiB  
Article
Effect of Notches on Fatigue Crack Initiation and Early Propagation Behaviors of a Ni-Based Superalloy at Elevated Temperatures
by Zuopeng Zhao, Xuteng Hu and Zhiwei Guo
Metals 2025, 15(4), 384; https://doi.org/10.3390/met15040384 - 29 Mar 2025
Viewed by 300
Abstract
The role of notch stress and surface defects on fatigue crack initiation and small-crack propagation behavior has been investigated using groove simulation specimens. The naturally initiated small-crack growth tests have been performed on a FGH4099 superalloy at 500 °C and 700 °C. The [...] Read more.
The role of notch stress and surface defects on fatigue crack initiation and small-crack propagation behavior has been investigated using groove simulation specimens. The naturally initiated small-crack growth tests have been performed on a FGH4099 superalloy at 500 °C and 700 °C. The findings indicate that elevated testing temperature significantly reduced the proportion of fatigue crack initiation life, with a less pronounced effect on the proportion of life for cracks to grow to First Engineering Crack size. Competing crack initiation modes were observed in the fatigue test of groove simulation specimens. The location of maximum principal stress was dominant fatigue crack initiation sites, and for specimens with surface inclusions, the defect location can also serve as a crack initiation site. Furthermore, crack initiation modes were found to have a more pronounced effect on the small-crack growth rate. A turning point observed in the crack growth rate curves for specimens with multi-site crack initiation was attributed to crack shielding and subsequent coalescence. Full article
(This article belongs to the Special Issue Fatigue Assessment of Metals)
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36 pages, 11072 KiB  
Article
An Approach to Evaluate the Fatigue Life of the Material of Liquefied Gases’ Vessels Based on the Time Dependence of Acoustic Emission Parameters: Part 1
by Oleg G. Perveitalov and Viktor V. Nosov
Metals 2025, 15(2), 148; https://doi.org/10.3390/met15020148 - 31 Jan 2025
Viewed by 726
Abstract
In the first part of this article devoted to the assessment of the fatigue life of structural steels at low temperatures, a study was conducted on the effect of pre-cycling in a low-cycle fatigue mode on the time dependences of acoustic emission parameters. [...] Read more.
In the first part of this article devoted to the assessment of the fatigue life of structural steels at low temperatures, a study was conducted on the effect of pre-cycling in a low-cycle fatigue mode on the time dependences of acoustic emission parameters. Commonly used St-3 steel was tested at −60 °C with varying durabilities, after which it was fractured once during static tests. The multilevel acoustic model used made it possible to estimate the structural parameter γ at the stage of elastoplastic deformation. The stage of active development of microcracks and their coalescence corresponds to a homogeneous fracture with stable acoustic emission characteristics (signal duration, amplitude variation coefficient, etc.). It was shown that regardless of the maximum voltage (460, 480, and 500 MPa) in the cycle and the operating times of up to 0.3, 0.5, and 0.7, the structural parameter remains within the known limits. The parameters of the Weibull law distribution and the logarithmically normal distribution for the coefficient γ were obtained, theoretical and calculated fatigue curves were plotted, and a method was proposed for evaluating the number of cycles before fracture under irregular loading conditions in the real operation of pressure vessels based on the “rainflow” cycles counting method. Full article
(This article belongs to the Special Issue Fatigue Assessment of Metals)
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20 pages, 23822 KiB  
Article
Fatigue Life Assessment of Corroded AlSi10MgMn Specimens
by Markus Schönowitz, Stefan Fladischer, Peter Oberreiter, Bernd Maier, Florian Grün and Kathrin Bauer-Troßmann
Metals 2024, 14(10), 1135; https://doi.org/10.3390/met14101135 - 5 Oct 2024
Viewed by 1014
Abstract
This study investigates the influence of pre-corrosion damage on the fatigue behavior of AlSi10MgMn high-pressure die-cast specimens, using the statistical distribution of corrosion depths. The analysis is conducted on two different surface conditions: an unmachined rough surface (Ra=5.05 [...] Read more.
This study investigates the influence of pre-corrosion damage on the fatigue behavior of AlSi10MgMn high-pressure die-cast specimens, using the statistical distribution of corrosion depths. The analysis is conducted on two different surface conditions: an unmachined rough surface (Ra=5.05μm) and a machined, polished surface (Ra=0.25μm). For the unmachined specimens, the corrosive damage manifests as homogeneously spread localized corrosion, whereas the polished specimens exhibit less uniform but deeper corrosion. The average corrosion depth of the polished specimens is found to be slightly higher (313 μm compared to 267 μm) with a broader depth distribution. Specimens are tested under a constant bending load amplitude in laboratory conditions at a stress ratio of R=0 until fracture. A fracture mechanics-based methodology is developed to assess the remaining fatigue life of corroded specimens, utilizing short and long crack fracture mechanical parameters derived from SENB specimens. This model incorporates a thickness reduction of the critical specimen cross-section based on the corrosion depth distribution and combines it with a small initial crack of the intrinsic defect size (aeff=14μm). Regardless of the surface condition, using the most frequent corrosion depth for thickness reduction provides a good estimate of the long-life fatigue strength, while using the 90th percentile depth allows for a conservative assessment. Full article
(This article belongs to the Special Issue Fatigue Assessment of Metals)
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13 pages, 12945 KiB  
Article
Physical Simulation of Mold Steels Repaired by Laser Beam Fusion Deposition
by Joel de Jesus, José A. M. Ferreira, Carlos Capela, José D. M. da Costa and Luís Borrego
Metals 2024, 14(6), 663; https://doi.org/10.3390/met14060663 - 3 Jun 2024
Viewed by 968
Abstract
In the present work, a study of the fatigue strength of two materials widely used in the production of molds, namely, the AISI P20 and AISI H13 steels, is presented. The tests were performed at a constant amplitude with a stress ratio of [...] Read more.
In the present work, a study of the fatigue strength of two materials widely used in the production of molds, namely, the AISI P20 and AISI H13 steels, is presented. The tests were performed at a constant amplitude with a stress ratio of R = 0 using samples where U-shaped notches were filled with laser beam fusion deposition. Three different sets of deposition parameters for each material were analyzed. Fatigue strength results are presented as S-N curves obtained for filled and non-filled materials. In addition to the assessment of the fatigue strength, metallography, hardness, and the fracture surface of the specimens tested were also evaluated. In general, a high number of metallurgic defects was detected, and consequently, a decrease in the mechanical properties of the materials was observed, especially the fatigue strength. However, the parameter optimization of the repairing laser process produced repaired zones with good metallurgical quality, leading to higher fatigue strength in both of the high-strength steels analyzed. Full article
(This article belongs to the Special Issue Fatigue Assessment of Metals)
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11 pages, 12566 KiB  
Article
Influence of Loading Waveform on the Fatigue Life of 34CrNi3MoVA Steel
by Xiaoyan Guan, Jie Tang and Jianzhi Chen
Metals 2024, 14(1), 110; https://doi.org/10.3390/met14010110 - 16 Jan 2024
Viewed by 1545
Abstract
Mechanical components often experience fatigue loading from various waveform conditions during their operational lifespan. However, the underlying mechanisms through which variations in loading waveform affect the fatigue life of components remain unclear. Thus, this study conducted tension–compression fatigue experiments on 34CrNi3MoVA steel specimens [...] Read more.
Mechanical components often experience fatigue loading from various waveform conditions during their operational lifespan. However, the underlying mechanisms through which variations in loading waveform affect the fatigue life of components remain unclear. Thus, this study conducted tension–compression fatigue experiments on 34CrNi3MoVA steel specimens under the same stress amplitude with different waveforms (cosine, triangular, sawtooth, and reverse sawtooth) to investigate the effects of loading waveform variations on the cyclic strain hardening behaviors, the fatigue fracture failure, and the fatigue life. The results indicated that specimens under different waveforms all exhibited cyclic strain hardening. The fatigue cyclic hardening level progressively increased in the order of cosine, triangular, and sawtooth waveforms, resulting in a continuous increase in cyclic saturation strain amplitude. The analysis of fatigue fractures demonstrated a consistent increase in both the initiation and propagation zone areas in the order of cosine, triangular, and sawtooth waveforms, and the boundary between the propagation and final fracture zones gradually shifted from a straight to a curved shape. The influence mechanisms of cyclic loading waveforms on the fatigue life of specimens were analyzed based on the energy dissipation, leading to the development of a universal fatigue life prediction model applicable to different waveform conditions, the model was then verified with the reverse sawtooth wave specimens and resulted in a prediction error less than 15%. The study is expected to serve as a significant guide for predicting and evaluating the fatigue life of mechanical components under various fatigue loading conditions. Full article
(This article belongs to the Special Issue Fatigue Assessment of Metals)
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