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Several studies have been conducted on the fatigue behavior of copper and 7-3, and 6-4 brasses. However, there have been fewer studies on the fatigue behavior and fatigue crack growth (FCG) properties of free-cutting brass, primarily because emphasis has been placed on the development of lead-free free-cutting brass. In this study, fatigue experiments were performed in the atmosphere at room temperature using three types of free-cutting, two types of bismuth (Bi)-based (with different grain sizes), and lead (Pb)-based brasses. It was found that lead-free Bi-based free-cutting brass had approximately the same fatigue performance as that of Pb-based free-cutting brass. It was also clarified that the addition of Bi or Pb initiated fatigue cracks, and that the crack growth period occupied most of the fatigue life. Differences in the FCG behavior of the three free-cutting brasses were observed in the low ΔK range. The modified linear fracture mechanics parameter M was used to quantitatively analyze the fatigue life and FCG behavior (short surface cracks). A comparison between the calculated and experimental results showed that M was useful.

In the Al alloy A2024-T3 extruded material, a rod-like structure is generated parallel to the extrusion direction. In this study, the effects of rod-like structures on fatigue crack initiation and growth behavior were comprehensively investigated. Two types of specimens were used in a fatigue experiment, in which the direction of the load stress amplitude was parallel (specimen P) and perpendicular (specimen V) to the rod-like structure. Based on the experimental and analytical results, the following findings were obtained regarding the fatigue life, location of crack initiation, and fatigue crack growth behavior. Because the fatigue life of specimen P was longer than that of specimen V, it is inferred that the rod-like structure significantly affects the fatigue life. In specimen P, fatigue cracks were generated from the grain boundaries of the Al matrix. By contrast, in specimen V, cracks were generated from the Cu–Mg-based intermetallic compound in the Al matrix. In specimen P, fatigue cracks were more likely to propagate across the rod-like structure, which decreased the fatigue crack growth rate. In specimen V, fatigue cracks did not propagate across the rod-like structure; instead, they propagated through the Al matrix. Therefore, the fatigue crack growth resistance of specimen V was lower than that of specimen P. The relationship between the fatigue crack growth rate and the modified linear elastic fracture mechanics parameter could be used to predict the S–N curve (stress amplitude vs. fatigue life) and fatigue crack growth behavior. The predicted results agreed well with the experimental results.

In this survey, the origin of fatigue crack initiation and damage evolution in different metallic materials is discussed with emphasis on the responsible microstructural mechanisms. After a historical introduction, the stages of cyclic deformation which precede the onset of fatigue damage are reviewed. Different types of cyclic slip irreversibilities in the bulk that eventually lead to the initiation of fatigue cracks are discussed. Examples of trans- and intercrystalline fatigue damage evolution in the low cycle, high cycle and ultrahigh cycle fatigue regimes in mono- and polycrystalline face-centred cubic and body-centred cubic metals and alloys and in different engineering materials are presented, and some microstructural models of fatigue crack initiation and early crack growth are discussed. The basic difficulties in defining the transition from the initiation to the growth of fatigue cracks are emphasized. In ultrahigh cycle fatigue at very low loading amplitudes, the initiation of fatigue cracks generally occupies a major fraction of fatigue life and is hence life controlling.

Weld defects such as porosity, inclusion, burn-through, and lack of penetration are difficult to detect and control effectively in an orthotropic steel deck (OSD), which will be a fatigue crack initiation site and lead to several fatigue cracking. The crack growth behavior in defective welded joints is different from that of defect-free joints. This study investigates crack–inclusion interaction for rib-to-deck welded joints in OSDs based on numerical simulation and linear elastic fracture mechanics (LEFM). A refined finite element model of a half U-rib with cracks and inclusions was established by using the FRANC3D-ABAQUS interactive technology. The full processes of the crack–inclusion interaction from approaching and penetrating were accurately simulated. Critical parameters, including the stress intensity factor (SIF), the shape factor, the growth rate, and the growth direction were analyzed. The stiff and soft inclusions amplify and shield the SIF of cracks when the crack grows to the local area of inclusions. During the entire process of crack growth, the soft and stiff inclusion accelerate and inhibit the crack growth, respectively. The stiff inclusion will lead to asymmetric growth of the crack shape, where the portion of the crack away from the inclusions has a higher growth rate. The soft and stiff inclusions will attract and repel the direction of crack growth at the proximal point, respectively.

Understanding short fatigue-crack propagation behavior is inevitable in the defect-tolerant design of structures. Short cracks propagate differently from long cracks, and the amount of crack closure plays a key role in the propagation behavior of short cracks. In the present paper, the buildup of fatigue-crack closure due to plasticity with crack extension from crack-like defects is simulated with a modified strip yield model, which leaves plastic stretch in the wake of the advancing crack. Crack-like defects are assumed to be closure-free and do not close even under compression. The effect of the size of crack-like defects on the growth and arrest of short cracks was systematically investigated and the cyclic R-curve derived. The cyclic R-curve determined under constant amplitude loading of multiple specimens is confirmed to be independent of the initial defect length. Load-shedding and ΔK-constant loading tests are employed to extend the cyclic R-curve beyond the fatigue limit determined under constant amplitude loading. The initiation stage of cracks is taken into account in R-curves when applied to smooth specimens.

This study presents an experimental methodology for characterizing the crack-tip region using high-resolution Digital Image Correlation (DIC). The approach utilizes a stereoscopic microscope setup combined with 3D-DIC analysis to enable precise measurements within the small-scale region surrounding the crack tip. Two nonlinear parameters are evaluated: the plastic component of the crack-tip opening displacement (CTODp) and the cyclic plastic zone size. The investigation was conducted on disk-shaped compact tension specimens made of AISI 1020 steel under constant-ΔK fatigue testing. The results demonstrate a strong correlation between these nonlinear parameters and fatigue crack propagation, which was maintained stable, validating the proposed methodology. Furthermore, the relevance of crack-tip plasticity in fatigue crack propagation is verified under the tested conditions, highlighting its utility for fatigue life assessment under complex loading scenarios.

Fatigue cracks that develop in civil infrastructure such as steel bridges due to repetitive loads pose a major threat to structural integrity. Despite being the most common practice for fatigue crack detection, human visual inspection is known to be labor intensive, time-consuming, and prone to error. In this study, a computer vision-based fatigue crack detection approach using a short video recorded under live loads by a moving consumer-grade camera is presented. The method detects fatigue crack by tracking surface motion and identifies the differential motion pattern caused by opening and closing of the fatigue crack. However, the global motion introduced by a moving camera in the recorded video is typically far greater than the actual motion associated with fatigue crack opening/closing, leading to false detection results. To overcome the challenge, global motion compensation (GMC) techniques are introduced to compensate for camera-induced movement. In particular, hierarchical model-based motion estimation is adopted for 2D videos with simple geometry and a new method is developed by extending the bundled camera paths approach for 3D videos with complex geometry. The proposed methodology is validated using two laboratory test setups for both in-plane and out-of-plane fatigue cracks. The results confirm the importance of motion compensation for both 2D and 3D videos and demonstrate the effectiveness of the proposed GMC methods as well as the subsequent crack detection algorithm.

Due to their distinct physical, chemical, and mechanical features, high-entropy alloys have significantly broadened the possibilities of designing metal materials, and are anticipated to hold a crucial position in key engineering domains such as aviation and aerospace. The fatigue performance of high-entropy alloys is a crucial aspect in assessing their applicability as a structural material with immense potential. This paper provides an overview of fatigue experiments conducted on high-entropy alloys in the past two decades, focusing on crack initiation behavior, crack propagation modes, and fatigue life prediction models.

The fatigue crack growth behavior of a submicron-grained WC–Co hardmetal is investigated by artificially introducing small flaws by means of sharp indentation. Similar fatigue testing is also conducted on notched specimens with long through-thickness cracks for comparison purposes. The use of controlled small indentations flaws is shown to be a valid and successful approach for studying and describing crack growth behavior under cyclic loading for the material under consideration. This statement is based on the similitude found in fatigue mechanics and mechanisms between both crack types. Regarding the former, accounting of the indentation-induced residual stresses is key to rationalize the experimental findings. Concerning the latter, inspection of crack-microstructure interaction as well as fracture surfaces permit to discern similar features and scenarios, at both meso- and micrometric length scales. Results from this research yield an immediate practical implication, as indentation techniques may then be proposed as an alternative testing route for investigating fatigue crack growth behavior of hardmetal grades where sharp indentation is capable to induce well-developed radial crack systems.

Fatigue failure is a common mode of deterioration for steel cables (e.g., 321 stainless steel) in cable‐stayed bridges. In this case, given that the FeCoNiCrMn high‐entropy alloy (HEA) coatings have been found to simultaneously improve the fatigue and corrosion resistance of 321 steel, the fatigue crack growth behavior of 321 steel coated with selective laser melting CoCrFeMnNi HEA was further studied in this work. The results indicate that the CoCrFeMnNi alloy coating is able to increase the fatigue crack growth resistance of 321 steel by 21.43% compared to the uncoated 321 steel, and this is because the initiation of crack is mitigated by the angular disparities between adjacent grains and an increased dislocation density in the coating. Furthermore, the acoustic emission (AE) technique was used to track fatigue damage and predict fatigue crack growth life. It was found that crack length could be effectively monitored and predicted using the count and energy parameter, suggesting material and stress ratio independence in the AE technique.