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Mechanical issues related to the information and growth of small cracks are considered to play a major role in very high cycle fatigue (VHCF) for metallic materials. Further efforts on better understanding in early stage of a crack are beneficial to estimating and preventing catastrophic damage for a long period service.

Dependent on the ultrasonic loading system, a novel method of in situ photomicroscope is established to study the crack behaviors in VHCF regime.

This in situ photomicroscope method provides advantages in combination with fatigue damage monitoring at high magnification, a large number of cycles, and efficiency. Visional investigation with attached image proceeding code proves that the method has high resolution on both size and time, which permits reliable accuracy on small crack growth rate. It is observed that the crack propagation trends slower in the overall small crack stage down to the level of 10–11 m/cycle. Strain analysis relays on a real-time recording which is applied by using digital image correlation. Infrared camera recording indicates the method is also suitable for thermodynamic study while growth of damage.

Benefiting from this method, it is more convenient and efficient to study the short crack propagation in VHCF regime.

The purpose of this paper is to determine the ultra-high cycle fatigue behavior and ultra-slow crack propagation behavior of selective laser melting (SLM) AlSi7Mg alloy under as-built conditions.

Constant amplitude and two-step variable amplitude fatigue tests were carried out using ultrasonic fatigue equipment. The fracture surface of the failure specimen was quantitatively analyzed by scanning electron microscope (SEM).

The results show that the competition of surface and interior crack initiation modes leads to a duplex S–N curve. Both manufacturing defects (such as the lack of fusion) and inclusions can act as initially fatal fatigue microcracks, and the fatigue sensitivity level decreases with the location, size and type of the maximum defects.

The research results play a certain role in understanding the ultra-high cycle fatigue behavior of additive manufacturing aluminum alloys. It can provide reference for improving the process parameters of SLM technology.

The study aims to examine the effect of inclusions and inherent microstructure on fatigue behavior of 34Cr2Ni2Mo steel.

Fatigue behavior of 34Cr2Ni2Mo steel was investigated for up to 1E10 cycles.

Results showed that both inclusion and inherent microstructure have an influence on the crack initiation mechanism. Fatigue cracks mostly initiated from inclusions, whereas substrate-induced crack initiations were also observed. Fatigue life of inclusion-induced failures is mostly determined by the location of inclusions rather than the loading stress. The inherent microstructure seems to tolerate inclusions at a lower stress level in very high-cycle regime owing to the absence of internal inclusion-induced failure. For the substrate-induced crack initiations, high-density dislocations are found to be accumulated around the carbide particle-matrix interface, which may be the cause of crack initiation in the inherent structure due to strain localization.

The effect of inclusions and inherent microstructure on fatigue behavior of 34Cr2Ni2Mo steel up to 1E10 cycles.

Highlights

• Fatigue failure occurs even at a lifetime of 5.76E9 cycles.

• Surface inclusion induced premature failures.

• Inherent microstructure tolerates inclusions at lower stress level.

• Internal carbides promote substrate-induced crack initiations.

Fatigue failure occurs even at a lifetime of 5.76E9 cycles.

Surface inclusion induced premature failures.

Inherent microstructure tolerates inclusions at lower stress level.

Internal carbides promote substrate-induced crack initiations.

The investigations could guide the structural design and fatigue life prediction of air-conditioning compressor valve plates.

The High-Cycle Fatigue (HCF) and Very-High-Cycle Fatigue (VHCF) behaviors of stainless steel used for air-conditioning compressor valve plates were investigated. Monotonic and cyclic loading conditions were designed to explore the fatigue responses according to the load characteristics of the structure.

The crack initiation can be observed as the arc-shaped cracks at both sides of specimens and Y-shaped crack bifurcation in the specimens. Moreover, the middle section and the cracks at both ends are not connected to the surface of the specimen. The stress-life results of the materials under two directions (vertical and horizontal) were provided to examine the difference in fatigue strength.

Monotonic and cyclic loading conditions were designed to explore the fatigue responses according to the load characteristics of the structure. Based on the experimental data, the results indicate that specimens under cyclic loading conditions could demonstrate better mechanical performance than static loadings.

The purpose of this paper is to present a study on effective methods for fatigue evaluation of composite structures.

Based on topological correspondence between half‐cycle arrays and the Haig diagrams, the fatigue data for composite structure in the form of array containing numbers of half‐cycles to failure (or in form of unitary damage array) are obtained. Such forms of the fatigue data facilitate significantly calculation of damage produced by any load spectrum (LS), presented as a half‐cycle array.

The loads of highest increments inside the operational range are of crucial importance for the fatigue life of composite structures, therefore it is possible to replace the whole LS with the equivalent loads of significantly reduced cycle numbers, which is very beneficial in the case when the fatigue life evidence is provided in the experimental way.

The paper presents novel evaluation methods for equivalent load cycles determination, consisting in application of unitary damage array, and simplified estimation procedure of fatigue properties on experimental basis.

The purpose of this paper is to determine (1) the relationship between microstructure and fatigue cracking behavior and (2) effect of rolling on the process of crack initiation and propagation in FeCrAl alloys.

The qualitative and quantitative fracture studies were performed using scanning electron microscopy and the non-contact optical measurement system (IFMG5).

The results show that the formation of facets, rough facets and parallel stripes in the crack initiation and early crack propagation zones are closely related to the sensitivity of crack behavior to the microstructure of the material. Besides, the rolling process has a significant influence on the small crack initiation and propagation behavior. Quantitative analysis demonstrates that the size of the stress intensity factor and plastic zone size in the rough zone is associated with the rolling process.

The findings of this study have the potential to enhance the understanding of the microstructural crack formation mechanisms in FeCrAl alloys and shed light on the impact of rolling on the long-term and ultra-long fatigue behavior of these alloys. This new knowledge is vital for improving manufacturing processes and ensuring the safety and reliability of FeCrAl alloys used in nuclear industry applications.

The investigations provide a basis for the optimization of the alloy 6061-T6 friction stir welding (FSW) process to improve the mechanical properties of welded joints.

The local deformation of the FSW joint in tension and fatigue test were experimentally investigated by digital image correlation (DIC) technique.

The local stress-strain behaviors of the sub-regions show that the plastic strain always concentrated at the heat affected zone (HAZ) on the advancing side both in tension and high cycle fatigue and eventually leads to the final fracture. The evolution of the plastic strain at very low stress is extremely slow and accounts for most of the total fatigue life. However, the local deformation exhibits a sudden increase just before the fatigue failure.

Based on the experimental data, the result indicates that the HAZ is the weakest zone across the weld and the strain localization in high cycle fatigue is very harmful and unpredictable for the FSW joints.

Two simple instruments for obtaining transient response from the frequency response in a vibrating system have been made available by Costain‐John Brown Ltd., Instrumentation Division, Roxby Place, Seagrave Road, Fulham, S.W.6. They consist respectively of Cosine and Sine cursors engraved on transparent plastic sheet, and are used in conjunction with special graph paper, on which the observed function is plotted. The method and its derivation arc described in a paper ‘An Approximate Method for obtaining Transient Reponse from Frequency Response’ by H. H. Roscnbrock, Proc. Inst. Elec. Engs., Vol. 102, Part B, No. 6, November 1955.

The purpose of the paper is to predict the residual life of liquid-storage tank to ensure safety and long-term service life of the structure.

The paper carried out the stress analysis of the wall plate and bottom plate of the liquid-storage tank, and the influence of circumferential stress on the tank is considered. On the other hand, considering the influence of the tank wall surface on the tank life, based on the Paris law, the surface processing coefficient and surface roughness coefficient are introduced to improve the Paris law.

The effectiveness of the improved model is verified by comparing with theoretical and experimental data, which provide a new method for the prediction of the remaining service life of the tank. Combined with the fatigue crack data in the test report and the calculated circumferential stress, the residual life of the storage tank is predicted.

The improved model provides a new method for the prediction of the remaining service life of the tank.

Model-assisted probability of detection (MAPOD) is an important approach used as part of assessing the reliability of nondestructive testing systems. The purpose of this paper is to apply the polynomial chaos-based Kriging (PCK) metamodeling method to MAPOD for the first time to enable efficient uncertainty propagation, which is currently a major bottleneck when using accurate physics-based models.

In this paper, the state-of-the-art Kriging, polynomial chaos expansions (PCE) and PCK are applied to “a^ vs a”-based MAPOD of ultrasonic testing (UT) benchmark problems. In particular, Kriging interpolation matches the observations well, while PCE is capable of capturing the global trend accurately. The proposed UP approach for MAPOD using PCK adopts the PCE bases as the trend function of the universal Kriging model, aiming at combining advantages of both metamodels.

To reach a pre-set accuracy threshold, the PCK method requires 50 per cent fewer training points than the PCE method, and around one order of magnitude fewer than Kriging for the test cases considered. The relative differences on the key MAPOD metrics compared with those from the physics-based models are controlled within 1 per cent.

The contributions of this work are the first application of PCK metamodel for MAPOD analysis, the first comparison between PCK with the current state-of-the-art metamodels for MAPOD and new MAPOD results for the UT benchmark cases.