Search Results (44)

This study presents a simulation-based damage modeling and fatigue risk assessment of a reusable ceramic matrix composite thruster designed for short-duration, green bipropellant propulsion systems. The thruster is constructed from a fiber-reinforced ultra-high temperature ceramic matrix composite composed of zirconium diboride, silicon carbide, and carbon fibers. Time-resolved thermal and structural simulations are conducted on a validated thruster geometry to characterize the severity of early-stage thermal shock, stress buildup, and potential degradation pathways. Unlike traditional fatigue studies that rely on empirical fatigue constants or Paris-law-based crack-growth models, this work introduces a simulation-derived stress-margin envelope methodology that incorporates ±20% variability in temperature-dependent material strength, offering a physically grounded yet conservative risk estimate. From this, a normalized risk index is derived to evaluate the likelihood of damage initiation in critical regions over the 0–10 s firing window. The results indicate that the convergent throat region experiences a peak thermal gradient rate of approximately 380 K/s, with the normalized thermal shock index exceeding 43. Stress margins in this region collapse by 2.3 s, while margin loss in the flange curvature appears near 8 s. These findings are mapped into green, yellow, and red risk bands to classify operational safety zones. All the results assume no active cooling, representing conservative operating limits. If regenerative or ablative cooling is implemented, these margins would improve significantly. The framework established here enables a transparent, reproducible methodology for evaluating lifetime safety in ceramic propulsion nozzles and serves as a foundational tool for fatigue-resilient component design in green space engines. Full article

This study provides a combined numerical and analytical investigation of fatigue crack growth in compact tension specimens made of 42CrMo4 steel. Through simulations in ANSYS Workbench (SMART Crack Growth module) and numerical modeling in MATLAB, the model is validated by comparing its results with the standard ASTM E399 and Paris’ law relationships. The effect of heat treatments and loading on crack growth rate was investigated. The results confirm the model’s applicability in predicting fatigue behavior in the linear–elastic region. Full article

This study examines fatigue crack growth behavior in induction-hardened S38C axle steel with a gradient microstructure. High-frequency three-point bending fatigue tests were conducted to evaluate crack growth rates (da/dN) across three depth-defined regions: a hardened layer, a heterogeneous transition zone, and a normalized core. Depth-resolved da/dN–ΔK relationships were established, and Paris Law parameters were extracted. The surface-hardened layer exhibited the lowest crack growth rates and flattest Paris slope, while the transition zone showed notable scatter due to microstructural heterogeneity and residual stress effects. These findings provide experimental insight into the fatigue performance of gradient-structured axle steels and offer guidance for fatigue life prediction and inspection planning. Full article

Based on the crack propagation rate test of LY12CZ aluminum alloy flat plate, the distribution characteristics of Paris formula parameters were characterized by the three-parameter logarithmic normal distribution, and a LY12CZ random crack propagation analysis method was established. By using the Monte-Carlo method to simulate the randomness of crack growth, a prediction model of the random crack propagation life of a thin porous plate with multiple site damage (MSD) was established and programmed. The model can accurately predict the crack growth life and failure probability of thin porous plates with MSD, which provides an effective engineering analysis method for the MSD evaluation of the thin plate structure with multiple holes. Full article

Navigable waterways play a vital role in the efficient transportation of millions of tons of cargo annually. Inland traffic must pass through a lock, which consists of miter gates. Failures and closures of these gates can significantly disrupt waterborne commerce. Miter gates often experience fatigue cracking due to their loading and welded connections. Repairing every crack can lead to excessive miter gate downtime and serious economic impacts. However, if the rate of crack growth is shown to be sufficiently slow, e.g., using Paris’ law, immediate repairs may be deemed unnecessary, and this downtime can be avoided. Paris’ law is often obtained from laboratory testing with detailed crack measurements of specimens with relatively simple geometry. However, Paris’ law parameters for an in situ structure will likely deviate from those predicted from physical testing due to variations in loading and materials and a far more complicated geometry. To improve Paris’ law parameter prediction, this research proposes a framework that utilizes (1) convenient vision-based tracking of crack evolution both in the laboratory and the field and (2) numerical model estimation of stress intensity factors (SIFs). This study’s methodology provides an efficient tool for Paris’ law parameter prediction that can be updated as more data become available through vision-based monitoring and provide actionable information about the criticality of existing cracks. Full article

The facture and fatigue behaviour of welded joints made of A516 Gr 60 was analysed, bearing in mind their susceptibility to cracking, especially in the case of components which had been in service for a long time period. With respect to fracture, the fracture toughness was determined for all three zones of a welded joint, the base metal (BM), heat-affected zone (HAZ) and weld metal (WM), by applying a standard procedure to evaluate K_Ic via based on J_Ic values (ASTM E1820). With respect to fatigue, the fatigue crack growth rates were determined according to the Paris law by the standard procedure (ASTM E647) to evaluate the behaviour of different welded joint zones under amplitude loading. The results obtained for A516 Gr. 60 structural steel showed why it is widely used in the case of static loads, since the minimum value of fracture toughness (185 MPa√m) provides relatively large critical crack lengths, whereas its behaviour under amplitude loading indicated a need for further improvement in WM and HAZ, since the crack growth rate reached values as high as 4.58 × 10⁻⁴ mm/cycle. In addition, risk-based analysis was applied to assess the structural integrity of a pressure vessel, including comparison with the high-strength low-alloy (HSLA) steel NIOVAL 50, proving once again its superior behaviour under static loading. Full article

Prolonged rolling contact fatigue between wheels and rails results in the formation of surface cracks on the rail and accurately analyzing the crack expansion behavior is essential to ensuring the safe operation of the train. Drawing upon the principles of fracture mechanics and finite element theory, this study establishes a finite element model of wheel–rail rolling contact that incorporates the presence of cracks. The method utilizes an interaction integral to calculate the stress intensity factors at the leading edge of the crack; then, the Paris formula is used to solve the crack spreading rate. It systematically examines the effects of the initial crack angle, the coefficient of friction of wheels to rails, and crack size on the behavior of fatigue crack propagation. The results indicate that the cracks primarily extend in the depth direction of the rail, transforming the semi-circular surface cracks into elliptical cracks with the major axis oriented along the rail’s width. Crack propagation is primarily driven by model II and III composite crack propagation, with their expansion rates influenced by operating conditions. In contrast, mode-I expansion is less sensitive to these conditions. Under single-variable loading conditions, a smaller initial crack angle results in a faster crack growth rate. Increasing crack length accelerates crack growth, while a higher friction coefficient inhibits it. Full article

Weathering steel possesses good atmospheric corrosion resistance and is increasingly applied in highway and railway bridges. The fatigue performance of the weld joint is an important issue in bridge engineering. This study experimentally investigates the microstructural properties and fracture crack growth behaviors of a Q370qENH bridge weathering steel weld joint. The FCG parameters of the base steel, butt weld, and HAZs, considering the effect of different plate thicknesses and stress ratios, are analyzed. Microstructural features, microhardness, and fatigue fracture surfaces are carefully inspected. The FCG rates of different weld regions in the stable crack growth stage are obtained using integral formulas based on the Paris and Walker law. The test results indicate that the heating and cooling process during the welding of Q370qENH steel creates improved microstructures with refined grain sizes and fewer impurities, thus leading to improved FCG performances in the HAZ and weld regions. The crack growth rate of Q370qENH weld regions increases with the stress ratio, and the influencing extent increasingly ranks as the base steel, HAZ, and the weld. The thick plate has a slightly slower fatigue crack growth rate for the Q370qENH weld joints. The Q370qENH base steel presents the highest fatigue crack growth rate, followed by the heat-treated and HAZ cases, while the weld area exhibits the lowest FCG rate. The Paris law coefficients of different regions of Q370qENH welds are presented. The collected data serve as a valuable reference for future analyses of fatigue crack propagation problems of Q370qENH steel bridge joints. Full article

For practical engineering structures, fatigue is one of the main factors affecting their safety and durability. Under long-term service conditions, the minor damage will be affected by fatigue loading and expand to macroscopic cracks, affecting the structure’s service performance. Based on the sensitivity of Lamb waves to minor and initial damage, a damage monitoring method for fatigue crack propagation is proposed. By carrying out fatigue crack propagation tests under constant amplitude loading, the Paris equation of 316L steel and damage signals at different crack growth stages were obtained. Combined with damage monitoring tests and finite element analysis, the relationship between the phase damage index (PDI), amplitude damage index (ADI), signal correlation coefficient, and fatigue crack propagation length was studied. Compared with PDI and ADI, the signal correlation coefficient is more sensitive to crack initiation, which can be selected as the damage monitoring index in the initial stage of crack growth. With the increase of fatigue crack propagation length, the peak time of the direct wave signal gradually moves backward, which shows an obvious phase change. In the whole fatigue crack growth stage, PDI and crack length show a monotonically changing trend. By using the stress intensity factor as the conversion parameter, a prediction model of the fatigue crack propagation rate based on PDI was established. Compared to the fatigue crack propagation rate measured by experiments, the relative error of the predicted results is 10%, which verifies the accuracy of the proposed damage monitoring method. Full article

In supporting the stable operation of high-penetration renewable energy grids, flywheel energy storage systems undergo frequent charge–discharge cycles, resulting in significant stress fluctuations in the rotor core. This paper investigates the fatigue life of flywheel energy storage rotors fabricated from 30Cr2Ni4MoV alloy steel, attempting to elucidate the material’s mechanical properties, crack propagation behavior, and impact of internal defects on fatigue life. Tensile tests reveal that the material exhibited high yield (992 MPa) and tensile strengths (1130 MPa). The Paris formula is used to model crack growth rates, ending in good agreement with the experimental data. Fatigue tests at various stress conditions highlight the material’s significant variability in fatigue life and emphasize the need for reliable design approaches. This paper also demonstrates that internal defect size and location critically affect fatigue life, calling for improvements in forging inspection standards. Overall, the present study provides a comprehensive analysis of 30Cr2Ni4MoV steel’s suitability for flywheel rotors, balancing safety, and operational efficiency. Full article

This paper presents a probabilistic method to predict fatigue crack growth for surface flaws in pipelines using a particle filtering method based on Bayes theorem. The random response of the fatigue behavior is updated continuously as measured data are accumulated by the particle filtering method. Fatigue crack growth is then predicted through an iterative process in which particles with a high probability are reproduced more during the update process, and particles with a lower probability are removed through a resampling procedure. The effectiveness of the particle filtering method was confirmed by controlling the depth and length direction of the cracks in the pipeline and predicting crack growth in one- and two-dimensional cases. In addition, the fatigue crack growth and remaining service life with a 90% confidence interval were predicted based on the findings of previous studies, and the relationship between the fatigue crack growth rate and the crack size was explained through the Paris’ law, which represents fatigue crack growth. Finally, the applicability of the particle filtering method under different diameters, aspect ratios, and materials was investigated by considering the negative correlation between the Paris’ law parameters. Full article

This study determines the equivalent stress intensity factor (SIF) model that best fits the experimental behavior of low-carbon steel under mixed modes ($I$ and $II$). The study assessed Tanaka, Richard, and Pook’s equivalent SIF models. The theoretical values used for comparison correspond to the experimental results in a modified C(T) geometry by machining a hole ahead of the crack tip subjected to fatigue loads with a load ratio of R = 0.1. The comparison involved the SIF for six experimental points and the values computed through the numerical simulation. The Paris, Klesnil, and Modified Forman–Newman crack growth models were used with each equivalent SIF to analyze the prediction in the estimated number of cycles. The Klesnil model showed the closest prediction since the error between the calculated and experimentally recorded number of cycles is the lowest. However, the material behavior reflects a reduced crack propagation rate attributed to plasticity in the crack tip. The results suggest that Asaro equivalent SIF conservatively estimates the element lifespan with increasing errors from 2.3% at the start of growth to 27% at the end of the calculation. This study sheds light on the accuracy and limitations of different equivalent SIF models, providing valuable insights for structural integrity assessments in engineering applications. Full article

In this paper, the fatigue crack growth rates of typical pressure vessel material 4130X under different corrosion conditions are investigated, and the effects of corrosion modes and loading frequency on the fatigue crack growth rate of 4130X are discussed. The results show that under the same loading conditions, the pre-corroded crack propagation rate is increased by 1.26 times compared with the uncorroded specimens. The plastic deformation mechanism of the crack tip in air is dominated by phase transformation but the hydrogen introduced by pre-corrosion causes a small number of dislocations at the crack tip. The crack growth rate obtained by corrosion fatigue is four times that of the uncorroded specimen, and the fracture surface shows a strong corrosion effect. The molecular dynamics simulation shows that the hydrogen atoms accumulated at the crack tip make the plastic deformation mechanism dominated by dislocation in the crack propagation process, and the coupling interaction between low frequency and the corrosion environment aggravates the hydrogen embrittlement of the crack tip. In the air condition, the loading frequency has no obvious effect on the crack growth rate: when the frequency decreases from 100 Hz to 0.01 Hz and other conditions remain unchanged, the fatigue crack growth rate increases by 1.5 times. The parameter n in the Paris expression is mainly influenced by frequency. The molecular dynamics simulation shows that low frequency promotes crack tip propagation. Full article

The assessment of fatigue is a crucial concern in welded components and structures. This study investigates the fatigue properties and models for predicting fatigue crack growth in Ti-6Al-4V titanium alloy when processed by vacuum brazing with TiCuNi filler. Fatigue properties and the impact of the stress ratio were determined through constant amplitude fatigue tests. By utilizing the results obtained from variable amplitude fatigue tests, various prediction models for fatigue crack growth were examined: modifications for load interaction, residual stress, and crack closure. The results indicate that the microstructures in the brazed zone consist of numerous fine, elongated needle-like Widmanstätten structures. In terms of cycle counting methods, the rainflow method outperforms the simple-range method. In the stable crack growth rate region, fatigue crack growth rate increases with the rise in stress ratio in a manner similar to high-strength steels. The Paris model without any modification obtains good predictions. For models modified with crack closure, the Elber model yields slightly better prediction results than the Schijve model. Among fatigue crack growth prediction models, the Willenborg model with residual stress modification produces the best results. Fracture surfaces within fatigued specimens’ brazed zones exhibit ductile failure characteristics, where fatigue striations and secondary cracks were observed. Full article

The fatigue crack growth rate (FCGR) of aluminium alloys under the combined influence of temperature and humidity remains a relatively unexplored area, receiving limited attention due to its intricate nature and challenges in predicting the combined impact of these factors. The challenge was to investigate and address the specific mechanisms and interactions between temperature and humidity, as in coastal environment conditions, on the FCGR of aluminium alloy. The present study conducts a comprehensive investigation into the combined influence of temperature and humidity on the FCGR of the Al6082 alloy. The fatigue pre-cracked compact tension specimens were corroded for 7 days and then subjected to various temperature and humidity conditions in a thermal chamber for 3 days to simulate coastal environments. The obtained data were analysed to determine the influence of temperature and humidity on the FCGR of the Al6082 alloy. An empirical model was also established to precisely predict fatigue life cycle values under these environmental conditions. The correlation between FCGR and fracture toughness models was also examined. The Al6082 alloy exhibits a 34% increase in the Paris constant C, indicating reduced FCGR resistance due to elevated temperature and humidity levels. At the same time, fatigue, corrosion, moisture-assisted crack propagation, and hydrogen embrittlement lead to a 27% decrease in threshold fracture toughness. The developed model exhibited accurate predictions for fatigue life cycles, and the correlation between fracture toughness and FCGR showed an error of less than 10%, indicating a strong relationship between these parameters. Full article