Probabilistic Estimation of Fatigue Strength for Axial and Bending Loading in High-Cycle Fatigue

A Novel Ultrasonic Fatigue Test and Application in Bending Fatigue of TC4 Titanium Alloy

The very high cycle fatigue (VHCF) problems of thin-plate structures are usually caused by high-frequency vibrations. This paper proposes an accelerated fatigue test method based on ultrasonic loading technology in order to develop a feasible bending testing method and explore the bending fatigue characteristics of thin-plate structures in the VHCF regime. A new bending fatigue specimen with an intrinsic frequency of 20 kHz was designed based on cantilever bending through finite element simulation. It was verified by the axial load test with R = -1. The results showed that the method could effectively transfer the dangerous cross-section at the first-order cantilever bending restraint to the internal part of the specimen, thereby making the fracture location independent of the complex stresses. The linear relationship between the vibration amplitude and the maximum stress was also verified using strain measurements. Furthermore, the S-N curves and fracture morphology for different loading types were consistent with conventional studies to a certain extent, which indicated that the design of the bending test model was reasonable.

An Experimental Analysis of the High-Cycle Fatigue Fracture of H13 Hot Forging Tool Steels

In this study, the axial fatigue behaviour of hot forging tool steels at room temperature was investigated. Fatigue tests were performed on two steels within the same H13 specification. The fatigue tests were carried out in the high-cycle fatigue domain under normal conditions. These tests were also performed on specimens in contact with a corrosive medium, applying stress values that led to the high-cycle fatigue domain under normal conditions for the sake of comparison. Both materials showed similar fatigue strengths when they were tested under normal conditions. In contrast, corrosion fatigue lives were much lower than in normal tests and differed significantly between the two steels. Crack initiation was triggered by microstructural and surface defects in the normal tests, whereas the formation of corrosion pits caused crack initiation in the corrosion fatigue tests. Moreover, a fracture surface analysis revealed dissimilar crack propagation areas between both steels, which suggested that both steels had different fracture toughness. These results were in line with the differences observed between the carbide and grain sizes of both of the material microstructures.

Statistical Assessment of Low-Cycle Fatigue Durability

This article presents an experimental–analytical statistical study of low-cycle fatigue to crack initiation and complete failure. The application of statistical and probability methods provides for the possibility of improving the characteristics related to the structural life and the justification for the respective values of cyclic loads in the design stage. Most studies investigating statistical descriptions of crack initiation or complete failure do not analyse the distribution of the characteristics, correlation relationships, and statistical parameters of low-cycle fatigue. Low-cycle failure may be quasistatic or (due to the fatigue) transient. Materials with contrasting cyclic properties were selected for the investigation: cyclically softening alloyed steel 15Cr2MoVA; cyclically stable structural steel C45; cyclically hardening aluminium alloy D16T1. All samples were produced in a single batch of each respective material to reduce the distribution of data. The lowest values of the variation coefficient of one of the key statistical indicators were obtained using the log-normal distribution, which is superior to the normal or Weibull distribution. Statistical analysis of the durability parameters showed that the distribution was smaller than the parameters of the distribution of the deformation diagram. The results obtained in the study enable the verification of durability and life of the structural elements of in-service facilities subjected to elastoplastic loading by assessing the distribution of characteristics of crack initiation and failure and low-cycle strain parameters as well as the permissible distribution limits.

Structural Materials Durability Statistical Assessment Taking into Account Threshold Sensitivity

This work presents an experimental—analytical study of the possibility of applying the method of the greatest probability to evaluate the sensitive thresholds of the bottom (N0) and top (Nk) of the statistical distribution of the mechanical structural characteristics. For the structural materials alloyed steel 15Cr2MoVA, steel C45 and aluminium alloy D16T1, the statistical distribution of proportional limit, yield strength, ultimate tensile strength, reduction in area, cyclic stress was estimated, as well as the following statistical parameters: mathematical mean, average square deviation, dispersion, asymmetry, variation coefficient, and excess. Purpose: to determine whether the limits of the sensitivity of the statistical distribution of the mechanical characteristics have been computed using the maximum likelihood method. Value: there is a certain upward and downward flattening of the probability curves in the statistical distribution curves of the fatigue test results. This implies that the chosen law of the distribution of random variables has an effect on the appearance of errors. These errors are unacceptable given the importance of accurately determining the reliability and durability of transport means, shipbuilding, machinery, and other important structures. Our results could potentially explain why sensitive limits cannot be applied to the statistical distribution of the mechanical characteristics of structural materials.

Statistical Estimation of Resistance to Cyclic Deformation of Structural Steels and Aluminum Alloy

Resistance to cyclic loading is a key property of the material that determines the operational reliability of the structures. When selecting a material for structures operating under low-cycle loading conditions, it is essential to know the cyclic deformation characteristics of the material. Low-cycle strain diagrams are very sensitive to variations in chemical composition, thermal processing technologies, surface hardening, loading conditions, and other factors of the material. The application of probability methods enables the increase in the life characteristics of the structures and the confirmation of the cycle load values at the design phase. Most research papers dealing with statistical descriptions of low-cycle strain properties do not look into the distribution of low-cycle diagram characteristics. The purpose of our paper is to provide a probability assessment of the low-cycle properties of materials extensively used in the automotive and aviation industries, taking into account the statistical assessment of the cyclic elastoplastic strain diagrams or of the parameters of the diagrams. Materials with contrasting cyclic properties were investigated in the paper. The findings of the research allow for a review of durability and life of the structural elements of service facilities subjected to elastoplastic loading by assessing the distribution of low-cycle strain parameters, as well as the allowed distribution limits.

Probability Assessment of the Mechanical and Low-Cycle Properties of Structural Steels and Aluminium

Key mechanical properties used in low-cycle strength and durability calculations are the strength (proportional limit stress, σpr; relative yield strength, σ0.2; and ultimate tensile stress, σu) and strain properties (proportional limit strain, epr; percent area reduction, ψ; and percent area reduction at failure, ψu). When selecting the key mechanical properties provided in the specifications, an error may be made due to the failure to account for a series of random factors that determine the distribution of properties. The majority of research papers dealing with statistical descriptions of the low-cycle strain properties do not look deeper into the distribution of mechanical properties and the diagram parameters of strain characteristics. This paper provides a description of the distribution patterns of mechanical properties, statistical parameters, and low-cycle fatigue curves. Log-normal distribution generated the lowest values for the coefficient of variation of one of the key statistical indicators, suggesting that log-normal distribution is superior to normal or Weibull distribution in this respect. The distribution of low-cycle strain parameters exceeded the distribution of mechanical properties considerably. Minimum coefficients of variation of the parameters were generated at normal distribution. The statistical analysis showed the lower distribution of the durability parameters compared to the distribution of parameters of the strain diagrams. The findings of the paper enable a revision of the durability and life of the structural elements of in-service facilities subject to elastoplastic loading by assessing the distribution of mechanical characteristics and low-cycle strain parameters as well as the permissible distribution limits.

Digital Scanning of Welds and Influence of Sampling Resolution on the Predicted Fatigue Performance: Modelling, Experiment and Simulation

Digital weld quality assurance systems are increasingly used to capture local geometrical variations that can be detrimental for the fatigue strength of welded components. In this study, a method is proposed to determine the required scanning sampling resolution for proper fatigue assessment. Based on FE analysis of laser-scanned welded joints, fatigue failure probabilities are computed using a Weakest-link fatigue model with experimentally determined parameters. By down-sampling of the scanning data in the FE simulations, it is shown that the uncertainty and error in the fatigue failure probability prediction increases with decreased sampling resolution. The required sampling resolution is thereafter determined by setting an allowable error in the predicted failure probability. A sampling resolution of 200 to 250 μm has been shown to be adequate for the fatigue-loaded welded joints investigated in the current study. The resolution requirements can be directly incorporated in production for continuous quality assurance of welded structures. The proposed probabilistic model used to derive the resolution requirement accurately captures the experimental fatigue strength distribution, with a correlation coefficient of 0.9 between model and experimental failure probabilities. This work therefore brings novelty by deriving sampling resolution requirements based on the influence of stochastic topographical variations on the fatigue strength distribution.

Statistical Size Effect in Fatigue Properties for Mini-Specimens

The study verifies the sensitivity of selected construction materials (S235JR structural steel and 1.4301 stainless steel) to the statistical size effect. The P–S–N curves were determined experimentally under high-cycle fatigue conditions for two specimen sizes (mini-specimen and standard specimen). The results were analyzed using a probabilistic model of the three-parameter Weibull cumulative distribution function. The analysis included the evaluation of the technological process effects on the results based on the material microstructure near the surface layer and the macro-fractography. The differences in the susceptibility to the size effect validated the applicability of the test method to mini-specimen and showed different populations of the distribution of critical material defects.