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Fatigue and Fracture of Metals and Alloys: Numerical and Experimental Study (3rd Edition)

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 August 2024 | Viewed by 3543

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Dr. Jarosłlaw Gałkiewicz

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Faculty of Mechatronics and Mechanical Engineering, Kielce University of Technology, Aleja Tysiaclecia Panstwa Polskiego 7, 25-314 Kielce, Poland
Interests: fracture mechanics; fatigue strength; constraint effects in fracture
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Lucjan Śnieżek

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Faculty of Mechanical Engineering, Military University and Technology, 2 Kaliskiego Street, 00-908 Warsaw, Poland
Interests: fatigue strength; friction stir welding; additive manufacturing technologies
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The success of our first two volumes of the Special Issue “Fatigue and Fracture of Metals and Alloys: Numerical and Experimental Study” underlines that the issues of fatigue and fracture mechanics are still open matters and require further research. This fact encouraged us to create a third Special Issue under the same title that will further develop the problem of the behaviour of structural elements under the influence of loads that lead to their destruction.

Fatigue and fracture can be analysed from different points of view. There is room here to study the structure of the material, influence of the environment, shape of the structural element, or type of load. Research can be conducted in the laboratory on real elements, but many analyses require a numerical approach that is often very advanced, thus requiring the creation of new tools. Similar to the process of studying the phenomena accompanying fatigue and cracking, extremely expensive and innovative tools are required, which have been presented many times in the previous Issues.

Thus, we invite everyone who works in this area to present their latest findings that provide a better understanding of the fracture and fatigue processes.

Dr. Jarosłlaw Gałkiewicz
Prof. Dr. Lucjan Śnieżek
Guest Editors

Manuscript Submission Information

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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. Materials is an international peer-reviewed open access semimonthly 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

fracture mechanics
fatigue
constraint effect
digital image correlation
fatigue strength

Published Papers (5 papers)

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Research

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13 pages, 13083 KiB

Open AccessArticle

Experimental Study on the Fatigue Crack Propagation Rate of 925A Steel for a Ship Rudder System

by Li Yu, Wenyong Guo, Chenghao Cao, Min Li, Zhe Wu, Te Wang, Hantao Chen and Xinglong Pan

Materials 2024, 17(8), 1808; https://doi.org/10.3390/ma17081808 - 15 Apr 2024

Viewed by 425

Abstract

The low-temperature fatigue crack propagation rate of 925A steel, as a rudder steel for polar special ships, has a crucial impact on the evaluation of the fatigue strength of polar ships. The purpose of this article is to study the fatigue crack propagation rate of 925A steel under different low-temperature conditions from room temperature (RT) to −60 °C. The material was subjected to fatigue crack propagation tests and stress intensity factor tests. The experimental tests were conducted according to the Chinese Standard of GB/T6398-2017. The results show that as the temperature decreases, the lifespan of 925A increases. Within a certain stress intensity factor, as the temperature decreases, the fatigue crack propagation rate decreases. At −60 °C, it exhibits ductile fracture; within normal polar temperatures, it can be determined that 925A meets the requirements for low-temperature fatigue crack propagation rates in polar regions. However, in some extreme polar temperatures below −60 °C, preventing brittle failure becomes a key focus of fatigue design. Finally, the fatigue crack propagation behavior at the microscale of 925A steel at low temperatures was described using fracture morphology. The experimental data can provide reference for the design of polar ships to further resist low-temperature fatigue and cold brittle fracture. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Metals and Alloys: Numerical and Experimental Study (3rd Edition))

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24 pages, 33744 KiB

Open AccessArticle

Experimental and Simulation Investigation on Fatigue Performance of H13 Steel Tools in Friction Stir Welding of Aluminum Alloys

by Ling Long, Xiaohong Zhang, Song Gu, Xiuxin Li, Xuefeng Cheng and Gaoqiang Chen

Materials 2024, 17(7), 1535; https://doi.org/10.3390/ma17071535 - 28 Mar 2024

Viewed by 470

Abstract

As the central component in friction stir welding, the design and manufacture of welding tools for aluminum alloys have garnered substantial attention. However, the understanding of tool reliability during the welding process, especially in terms of fatigue performance, remains unclear. This paper focuses on the welding of AA2219-T4 as a case study to elucidate the predominant failure mode of the tool during the friction stir welding (FSW) of aluminum alloys. Experimental methods, including FSW welding and fracture morphology analysis of the failed tool, coupled with numerical simulation, confirm that high-cycle mechanical fatigue fracture is the primary mode of the tool failure. Failures predominantly occur at the tool pin’s root and the shoulder end face with scroll concave grooves. The experimental and simulation results exhibit a noteworthy agreement, validating the reliability of the simulation model. The FSW Arbitrary Lagrangian–Eulerian (ALE) model developed in this study analyzes stress distribution and variation under the thermo-mechanical coupling effect of the tool. It reveals that stress concentration resulting from structural changes in the tool is the primary driver of fatigue crack initiation. This is attributed to exposure to alternating cyclic stresses such as bending, tension, and torsion at the tool pin’s root, manifesting as multiaxial composite mechanical fatigue. Among these stresses, bending alternating cyclic stress exerts the most significant influence. The paper employs the Tool Life module in DEFORM software to predict the fatigue life of the tool. Results indicate that reducing welding speed or increasing rotation speed can enhance the tool’s fatigue life to some extent. The methodology proposed in this paper serves as a valuable reference for optimizing FSW structures or processes to enhance the fatigue performance of welding tools. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Metals and Alloys: Numerical and Experimental Study (3rd Edition))

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12 pages, 5795 KiB

Open AccessArticle

Effect of Strain Rate on Hydrogen Embrittlement of Ti6Al4V Alloy

by Tien-Dung Nguyen, Nooruddin Ansari, Keun Hyung Lee, Dong-Hyun Lee, Jun Hyun Han and Soo Yeol Lee

Materials 2024, 17(5), 1100; https://doi.org/10.3390/ma17051100 - 28 Feb 2024

Viewed by 665

Abstract

The phenomenon of hydrogen embrittlement (HE) in metals and alloys, which determines the performance of components in hydrogen environments, has recently been drawing considerable attention. This study explores the interplay between strain rates and solute hydrogen in inducing HE of Ti6Al4V alloy. For the hydrogen-charged sample, as the strain rate was decreased from 10⁻²/s to 10⁻⁵/s, the ductility decreased significantly, but the HE effect on mechanical strength was negligible. The low strain rate (LSR) conditions facilitated the development of high-angle grain boundaries, providing more pathways for hydrogen diffusion and accumulation. The presence of solute hydrogen intensified the formation of nano/micro-voids and intergranular cracking tendencies, with micro-crack occurrences observed exclusively in the LSR conditions. These factors expanded the brittle hydrogen-damaged region more deeply into the interior of the lattice. This, in turn, accelerated both crack initiation and intergranular crack propagation, finally resulting in a considerable HE effect and a reduction in ductility at the LSR. The current study underscores the influence of strain rate on HE, enhancing the predictability of longevity and improving the reliability of components operating in hydrogen-rich environments under various loading conditions. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Metals and Alloys: Numerical and Experimental Study (3rd Edition))

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17 pages, 6618 KiB

Open AccessArticle

Damage-Accumulation-Induced Crack Propagation and Fatigue Life Analysis of a Porous LY12 Aluminum Alloy Plate

by Cheng Lv, Kejie Wang, Xiang Zhao and Fenghui Wang

Materials 2024, 17(1), 192; https://doi.org/10.3390/ma17010192 - 29 Dec 2023

Cited by 1 | Viewed by 615

Abstract

Rivets are usually used to connect the skin of an aircraft with joints such as frames and stringers, so the skin of the connection part is a porous structure. During the service of the aircraft, cracks appear in some difficult-to-detect parts of the skin porous structure, which causes great difficulties in the service life prediction and health monitoring of the aircraft. In this paper, a secondary development subroutine in PYTHON based on ABAQUS-XFEM is compiled to analyze the cracks that are difficult to monitor in the porous structure of aircraft skin joints. The program can automatically analyze the stress intensity factor of the crack tip with different lengths in the porous structure, and then the residual fatigue life can be deduced. For the sake of safety, the program adopts a more conservative algorithm. In comparison with the physical fatigue test results, the fatigue life of the simulation results is 16% smaller. This project provides a feasible simulation method for fatigue life prediction of porous structures. It lays a foundation for the subsequent establishment of digital twins for damage monitoring of aircraft porous structures. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Metals and Alloys: Numerical and Experimental Study (3rd Edition))

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Review

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23 pages, 17686 KiB

Open AccessReview

An Overview on Fatigue of High-Entropy Alloys

by Junchao Hu, Xue Li, Qiuchen Zhao, Yangrui Chen, Kun Yang and Qingyuan Wang

Materials 2023, 16(24), 7552; https://doi.org/10.3390/ma16247552 - 7 Dec 2023

Cited by 2 | Viewed by 921

Abstract

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. Full article

(This article belongs to the Special Issue Fatigue and Fracture of Metals and Alloys: Numerical and Experimental Study (3rd Edition))

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