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Metals
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Fatigue Life Prediction of Metallic Materials
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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 (31 January 2021) | Viewed by 24719

Special Issue Editors

Prof. Dr. Jernej Klemenc

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, SI-1000 Ljubljana, Slovenia
Interests: fatigue of metals; polymers and hybrid structures; fatigue of AM structures; fatigue life prediction; reliability; accelerated testing; statistical modeling; artificial intelligence; vehicle dynamics
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Marko Nagode

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, SI-1000 Ljubljana, Slovenia
Interests: thermo-mechanical fatigue; fatigue life prediction; creep life prediction; finite element analysis; cyclic plasticity; reliability; finite mixture modelling; optimization
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The study of metal fatigue can be traced back to 1870, when a German, August Wöhler, first published his work on the fatigue of iron and steel. In the following decades, the topic attracted significant interest, because fatigue failures are one of the most frequent damage phenomena when structures are exposed to dynamic loading. Consequently, the development of new products in transport industry, construction industry, machine-tools industry and medical-implants industry requires the consideration of fatigue-based design. Despite the significant body of research related to the fatigue of metallic materials, and the fact that polymer materials often replace metals in consumer products, the fatigue-life prediction of metallic materials still remains an interesting research topic. The increased accessibility of high-performance computing, the invention of new metallic alloys or functional materials (e.g., shape-memory alloys), and the development of new production technologies (e.g., additive manufacturing) and joining techniques represent daily challenges for the improvement of existing fatigue-design methods and the development of new and innovative approaches for the effective prediction of the stress–strain response and fatigue life. Therefore, we invite researchers to submit manuscripts related to the fatigue life prediction of metallic materials to this Special Issue of Metals. Articles contributing to either high-cycle or low-cycle fatigue are welcome.

Prof. Dr. Jernej Klemenc
Prof. Dr. Marko Nagode
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 of light-weight metals and alloys
  • fatigue of shape-memory alloys
  • fatigue of metallic medical implants
  • fatigue of additively manufactured structures
  • fatigue of cellular structures
  • fatigue of joint structures
  • thermo-mechanical fatigue of metals
  • fracture mechanics of metals
  • modeling of cyclic elastic-plastic material behavior
  • predicting fatigue life

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Published Papers (7 papers)

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Research

20 pages, 5803 KiB  
Article
Analysis of Additional Load and Fatigue Life of Preloaded Bolts in a Flange Joint Considering a Bolt Bending Load
by Ivan Okorn, Marko Nagode, Jernej Klemenc and Simon Oman
Metals 2021, 11(3), 449; https://doi.org/10.3390/met11030449 - 9 Mar 2021
Cited by 15 | Viewed by 6752
Abstract
The influence of the working load on the dynamic loading of the bolt was investigated in our study for two cases of flange joints. The analytical calculation according to the Verein Deutscher Ingenieure (VDI) 2230 recommendation and the numerical analysis using the finite [...] Read more.
The influence of the working load on the dynamic loading of the bolt was investigated in our study for two cases of flange joints. The analytical calculation according to the Verein Deutscher Ingenieure (VDI) 2230 recommendation and the numerical analysis using the finite element method (FEM) were performed for a model of a four-bolt joint. To verify the FEM analysis, the forces in the bolts were measured during preloading and during the application of the working load on the test rig. Based on the analytical and numerical results, the influence of the working load application point on the bolt load and its fatigue life was analysed for different cases. Comparison of the results shows that the analytical method overestimates the additional bolt stresses at low working load, mainly due to the extremely large fraction of bending stress. As the working load increases, the differences between the two methods decrease, but only for the reason that the analytical method can only linearly scale the overestimated results at lower working load, and FEM analysis, on the other hand, shows a progressive increase of the additional stress in the bolt at higher working loads due to the spreading of the flange. It is also shown that a high washer significantly increases the fatigue life of the bolt for two reasons: (i) a high washer reduces the additional stress in the bolt, and (ii) the high washer shifts the critical fatigue point from the thread area to the transition of the bolt shank to the head. Full article
(This article belongs to the Special Issue Fatigue Life Prediction of Metallic Materials)
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22 pages, 6742 KiB  
Article
Fatigue Models Based on Real Load Spectra and Corrected S-N Curve for Estimating the Residual Service Life of the Remanufactured Excavator Beam
by Gang Zhao, Junsong Xiao and Qi Zhou
Metals 2021, 11(2), 365; https://doi.org/10.3390/met11020365 - 22 Feb 2021
Cited by 3 | Viewed by 3052
Abstract
To more accurately predict the residual fatigue cycles and estimate the service life of the remanufactured excavator, the fatigue models integrating the corrected S-N curve, the RFC algorithm, the FEA model, and the mechanism dynamic model are established depending on the real load [...] Read more.
To more accurately predict the residual fatigue cycles and estimate the service life of the remanufactured excavator, the fatigue models integrating the corrected S-N curve, the RFC algorithm, the FEA model, and the mechanism dynamic model are established depending on the real load spectra under experimental working conditions and the corrected S-N curve of the beam metal remanufactured with the welding process. Depending on the test data of the unidirectional stress history and the servo displacements of the major cylinders, the mechanism dynamic model was first established to illustrate the real load spectra applied on the pivots of the working beam. The load spectra are further used in the finite element analysis (FEA) model to obtain the stress contours of the beam relevant to the sampling time, which is the stress spectra at any nodes on the beam in theory. Subsequently, the rain flow counting (RFC) algorithm based on the dual parameters of the cyclic stress amplitude and mean is established to provide the frequency spectra in the longevity region on the beam. Furthermore, due to the fatigue property changes of the beam metal remanufactured with the welding process, its S-N curve is corrected based on the detail fatigue rating (DFR) method to compute the stress cycles at each stress level on the crisis nodes. Finally, the total stress cycles that can be burdened by the remanufactured beam is computed under the Miner’s linear fatigue cumulative criterion. The total number of stress cycles is eventually converted to the fatigue and service life depending on the proportion of the sampling time under relevant working conditions. The results show that integrated fatigue models provide a practical approach to enhancing the accuracy of the estimation on the residual service life of the remanufactured excavator beam. It is significant for improving the reliability and safety of the remanufactured excavator. Full article
(This article belongs to the Special Issue Fatigue Life Prediction of Metallic Materials)
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21 pages, 3868 KiB  
Article
Predicting the Fatigue Life of an AlSi9Cu3 Porous Alloy Using a Vector-Segmentation Technique for a Geometric Parameterisation of the Macro Pores
by Dejan Tomažinčič, Žiga Virk, Peter Marijan Kink, Gregor Jerše and Jernej Klemenc
Metals 2021, 11(1), 72; https://doi.org/10.3390/met11010072 - 31 Dec 2020
Cited by 3 | Viewed by 2986
Abstract
Most of the published research work related to the fatigue life of porous, high-pressure, die-cast structures is limited to a consideration of individual isolated pores. The focus of this article is on calculating the fatigue life of high-pressure, die-cast, AlSi9Cu3 parts with many [...] Read more.
Most of the published research work related to the fatigue life of porous, high-pressure, die-cast structures is limited to a consideration of individual isolated pores. The focus of this article is on calculating the fatigue life of high-pressure, die-cast, AlSi9Cu3 parts with many clustered macro pores. The core of the presented methodology is a geometric parameterisation of the pores using a vector-segmentation technique. The input for the vector segmentation is a μ-CT scan of the porous material. After the pores are localised, they are parameterised as 3D ellipsoids with the corresponding orientations in the Euclidian space. The extracted ellipsoids together with the outer contour are then used to build a finite-element mesh of the porous structure. The stress–strain distribution is calculated using Abaqus and the fatigue life is predicted using SIMULIA fe-safe. The numerical results are compared to the experimentally determined fatigue lives to prove the applicability of the proposed approach. The outcome of this research is a usable tool for estimating the limiting quantity of a structure’s porosity that still allows for the functional performance and required durability of a product. Full article
(This article belongs to the Special Issue Fatigue Life Prediction of Metallic Materials)
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18 pages, 55659 KiB  
Article
An Analytical Model for Predicting the Stress Intensity Factor of Single-Hole-Edge Crack in Diffusion Bonding Laminates with Preset Unbonded Area
by Yang Liu and Shutian Liu
Metals 2020, 10(11), 1526; https://doi.org/10.3390/met10111526 - 17 Nov 2020
Cited by 2 | Viewed by 1702
Abstract
The diffusion bonding titanium alloy laminates with preset unbonded area (DBTALPUA) compared with other titanium alloy structural forms has good damage tolerance performance and designability. It is important to fast get the damage estimation of the DBTALPUA with crack. The stress intensity factor [...] Read more.
The diffusion bonding titanium alloy laminates with preset unbonded area (DBTALPUA) compared with other titanium alloy structural forms has good damage tolerance performance and designability. It is important to fast get the damage estimation of the DBTALPUA with crack. The stress intensity factor (SIF) of the crack is an effective indicator to give the damage estimation. In order to get the SIF fast, this paper proposed an analytical model to calculate SIF for single hole-edge crack in DBTALPUA with hole under tension loading. Comparison of the results obtained through this analytical model and numerical simulation illustrated that the analytical model can rapidly predict the SIF with fine precision. Full article
(This article belongs to the Special Issue Fatigue Life Prediction of Metallic Materials)
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21 pages, 17182 KiB  
Article
Adaptive Finite Element Prediction of Fatigue Life and Crack Path in 2D Structural Components
by Abdullateef H. Bashiri and Abdulnaser M. Alshoaibi
Metals 2020, 10(10), 1316; https://doi.org/10.3390/met10101316 - 1 Oct 2020
Cited by 13 | Viewed by 3240
Abstract
The existence of a hole near a growing fatigue crack can cause the crack trajectory to deviate. Unless the hole is too close to the crack, the crack is arrested at the edge of the hole and does not progress further. The purpose [...] Read more.
The existence of a hole near a growing fatigue crack can cause the crack trajectory to deviate. Unless the hole is too close to the crack, the crack is arrested at the edge of the hole and does not progress further. The purpose of this paper was to predict the crack propagation and lifetime of two-dimension geometries for linear elastic materials in mixed-mode loading using a finite element source code program written in Visual Fortran language. The finite element mesh is generated using the advancing front method. The onset criterion of crack propagation was based on the equivalent stress intensity factor which provides the most important parameter that must be accurately estimated for the mixed-mode loading condition. The maximum circumferential stress theory was used as a direction criterion. The modified compact tension (MCTS) was studied to demonstrate the influence of the hole’s presence on the direction of crack growth and fatigue life for different configurations. The Paris’ law model has been employed to evaluate the mixed-mode fatigue life for MCTS in different configurations under the linear elastic fracture mechanics (LEFMs) assumption. The framework involves a progressive crack extension study of stress intensity factors (SIFs), crack growth direction, and fatigue life estimation. The results show that the fatigue growth was attracted to the hole either changes its direction to reach the hole or floats by the hole and grows as the hole is missed. The results of the study agree with several crack propagation experiments in the literature revealing similar crack propagation trajectory observations. Full article
(This article belongs to the Special Issue Fatigue Life Prediction of Metallic Materials)
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17 pages, 2535 KiB  
Article
Uncertainty Quantification in Small-Timescale Model-Based Fatigue Crack Growth Analysis Using a Stochastic Collocation Method
by Hesheng Tang, Xueyuan Guo and Songtao Xue
Metals 2020, 10(5), 646; https://doi.org/10.3390/met10050646 - 16 May 2020
Cited by 6 | Viewed by 2931
Abstract
Due to the uncertainties originating from the underlying physical model, material properties and the measurement data in fatigue crack growth (FCG) processing, the prediction of fatigue crack growth lifetime is still challenging. The objective of this paper was to investigate a methodology for [...] Read more.
Due to the uncertainties originating from the underlying physical model, material properties and the measurement data in fatigue crack growth (FCG) processing, the prediction of fatigue crack growth lifetime is still challenging. The objective of this paper was to investigate a methodology for uncertainty quantification in FCG analysis and probabilistic remaining useful life prediction. A small-timescale growth model for the fracture mechanics-based analysis and predicting crack-growth lifetime is studied. A stochastic collocation method is used to alleviate the computational difficulties in the uncertainty quantification in the small-timescale model-based FCG analysis, which is derived from tensor products based on the solution of deterministic FCG problems on sparse grids of collocation point sets in random space. The proposed method is applied to the prediction of fatigue crack growth lifetime of Al7075-T6 alloy plates and verified by fatigue crack-growth experiments. The results show that the proposed method has the advantage of computational efficiency in uncertainty quantification of remaining life prediction of FCG. Full article
(This article belongs to the Special Issue Fatigue Life Prediction of Metallic Materials)
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12 pages, 2256 KiB  
Article
A Methodology for Incorporating the Effect of Grain Size on the Energy Efficiency Coefficient for Fatigue Crack Initiation Estimation in Polycrystalline Metal
by Chun-Yu Ou, Rohit Voothaluru and C. Richard Liu
Metals 2020, 10(3), 355; https://doi.org/10.3390/met10030355 - 9 Mar 2020
Cited by 3 | Viewed by 2666
Abstract
Estimating fatigue crack initiation of applied loading is challenging due to the large number of individual entities within a microstructure that could affect the accumulation of dislocations. In order to improve the prediction accuracy of fatigue crack initiation models, it is essential to [...] Read more.
Estimating fatigue crack initiation of applied loading is challenging due to the large number of individual entities within a microstructure that could affect the accumulation of dislocations. In order to improve the prediction accuracy of fatigue crack initiation models, it is essential to accurately compute the energy dissipated into the microstructure per fatigue loading cycle. The extent of the energy dissipated within the microstructure as a fraction of the overall energy imparted by loading has previously been defined as the ‘energy efficiency coefficient’. This work studied the energy efficiency coefficient as a factor in the measurement of accumulated plastic strain energy stored at the crack initiation site during cyclic loading. In particular, the crystal plasticity constitutive formulation was known as ’length scale independent’ previously. As a result, a semi-empirical approach was presented whereby the potential effect of grain size can be accounted for without the use of a strain gradient plasticity approach. The randomized representative volume elements were created based on the experimental analysis of grain size distribution. The work was aimed at capturing some of the effects of grain size and utilizing them to complete a semi-empirical estimation of crack initiation in polycrystalline materials. The computational methodology ensured the representative of microstructural properties, including the elastic constant and critical resolved shear stress via appreciable fit achieved with the empirical tensile test results. Crystal plasticity finite element modeling was incorporated into a finite element code to estimate the potential for crack initiation. The energy efficiency coefficient was computed for a class of material with grain size to C11000 electrolytic tough pitch (ETP) copper. This methodology can improve fatigue crack initiation life estimation and advance the fundamental study of energy efficiency coefficient during fatigue crack initiation. Full article
(This article belongs to the Special Issue Fatigue Life Prediction of Metallic Materials)
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