FATIGUE 2024
VOLUME I
Proceedings of the 9th Engineering Integrity Society
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ISBN 978-0-9544368-7-2
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PREFACE
Over the last 40 years, the Engineering Integrity Society has established a distinctive culture of bringing together practising engineers and researchers from industry and academia to share insights, understanding and expertise. Throughout this time we have organised workshops, seminars, exhibitions and conferences and Fatigue 2024 is our ninth international conference.
Fatigue 2024 continues with the themes established in previous conferences to support the international fatigue and durability community. Participants at the conference will share knowledge and understanding of the challenges of using high performance materials for reliable, cost effective products. The papers presented will examine the interplay between the latest manufacturing processes, the properties of materials, and the integrity and performance of components operating in challenging conditions. The complex relationship between materials, process and manufacturing routes and the durability and reliability of the machines and devices forms the central theme of the conference.
The EIS is a registered charity and one of our aims is to encourage young people to consider careers in the engineering professions. We are pleased that almost one third of the papers at Fatigue 2024 have been written and presented by early career engineers eligible for the Peter Watson Prize, which we award annually in memory of our Founding President.
Dr John Yates Conference Convenor
Front cover image acknowledgement:
K. Wackermann, F. Ebling, T. Michler, F. Schweize & H. Oesterlin (abstract #26.1)
The success of any conference depends on many factors, not least an enthusiastic and efficient team of organisers in the background. To this end, I must pay tribute to the following for their commitment, support and in the case of the Local Technical Committee, valuable time and effort spent reviewing the papers submitted for the proceedings:
Conference Secretariat:
Mrs Sara Atkin
Conference Organising Committee:
Dr John Yates
Dr Hollie Cockings
Assoc. Professor Svjetlana Stekovic
Sara Atkin
Conference Convenor:
Dr John Yates
Deputy Convenors:
Dr Hollie Cockings
Assoc. Professor Svjetlana Stekovic
Local Technical Committee:
Dr Amir Chahardehi
Andrew Blows
Assoc Prof Chris Hyde
Dr Chuanjie Cui
Dr Emilio Martínez-Pañeda
Dr Fabien Lefebvre
Dr Farnoosh Farhad
Prof Filippo Berto
Prof Francisco A Diaz
Prof Hassan Ghadbeigi
Dr Hayder Ahmad
Dr Hollie Cockings
Dr James Rouse
Dr John Yates
Prof Mark Whittaker
Dr Mohamed Bennebach
Naveed Sheikh
Dr Pablo Lopez-Crespo
Paul Roberts
Dr Peter Bailey
Robert Cawte
Dr Spencer Jeffs
Assoc Prof Svjetlana Stekovic
Dr Yi Gao
International Scientific Committee:
Alan Hellier (Australia)
Alberto Campagnolo (Italy)
Alfredo Navarro (Spain)
Ali Fatemi (USA)
André Galtier (France)
Andrea Carpinteri (Italy)
Andrea Spagnoli (Italy)
Barbara Rossi (UK)
Chris Hyde (UK)
Christophe Pinna (UK)
Daolun Chen (Canada)
David Nowell (UK)
Ken Wackermann (Germany)
Fabien Lefebvre (France)
Filippo Berto (Italy)
Francesco Iacoviello (Italy)
Francisco A Diaz (Spain)
Frank Walther (Germany)
Harry Bhadeshia (UK)
Hellmuth Klingelhoeffer (Germany)
Hossein Farrahi (Iran)
James Marrow (UK)
James Newman (USA)
Jan Papuga (Czech Republic)
Johan Moverare (Sweden)
Liviu Marsavina (Romania)
Luca Susmel (UK)
Marc Geers (The Netherlands)
Mark Whittaker (UK)
Martin Bache (UK)
Matteo Benedetti (Italy)
Matteo Luca Facchinetti (France)
Mike Fitzpatrick (UK)
Miloslav Kepka (Czech Republic)
Muhsin J Jweeg (Iraq)
Neil James (UK)
Pablo Lopez-Crespo (Spain)
Paul Bowen (UK)
Phil Withers (UK)
Philippa Reed (UK)
Reinhard Pippan (Austria)
Rob Ritchie (USA)
Robert Akid (UK)
Sabrina Vantadori (Italy)
Shahrum Abdullah (Malaysia)
Svjetlana Stekovic (Sweden)
Takashi Nakamura (Japan)
Thierry Palin-Luc (France)
Veronique Doquet (France)
Wim de Waele (Belgium)
Yee Han Tai (UK)
Yoshihiko Uematsu (Japan)
Youshi Hong (China)
Yukitaka Murakami (Japan)
Headline Sponsor: ZwickRoell
Conference Sponsors: Altair
Beta CAE Systems
Darvick
Dassault Systèmes Simulia
Hottinger Bruel & Kjaer UK
Instron
Kent
Severn Thermal Solutions
Swansea Materials Research & Testing Ltd (SMaRT)
STEP Lab
Texys Group
TWI
2: ADDITIVE MANUFACTURING I
Fatigue strength characterisation of wire+arc additively manufactured steel components and the relation with manufacturing imperfections
R. Motte, V. Rappe, R. Nunes, W. Verlinde & W. de Waele...................................................................................................................11
3: TESTING
Refinement of cyclic R-curve determination on extrinsically short cracks by annealing
L. Walch, T. Klünsner, G. Ressel, A. Hohenwarter & R. Pippan..........................................................................................................23
4: IMAGING
In-situ full-field strain mapping by high resolution EBSD and J-integral analysis of a short fatigue crack in single-crystal Nickel X. Su, R. Scales, A. Koko, J. Gong & T. J. Marrow..............................................................................................................................33
5: JOINTS
A practical approach for the fatigue life estimation of hybrid joints through testing and numerical simulations
C. Bagni, A. Halfpenny, M. Hill & A. Tarasek.....................................................................................................................................44
An investigation into fatigue failure and self-loosening of bolted joints subjected to transverse vibration
S. Hashimura & A. Saito......................................................................................................................................................................58
A practical methodology for the fatigue testing of hybrid joints
A. Pierpoint, M. Hill & C. Bagni..........................................................................................................................................................70
6: PROBABILISTIC MODELLING
A probabilistic fatigue model using Gaussian processes and its application to additively manufactured metals M. Schultz, H. Erdelyi, M. Hack, S. Straesser & N. Lammens............................................................................................................83
3Dprint AM35 wire arc additively manufactured milled specimens under fatigue B. Karabulut, X. Ruan, S. MacDonald, J. Dobric & B. Rossi........ 92
A comparative investigation on the uniaxial plain and notch fatigue strengths of heavy-section castings made of pearlitic and highsilicon ferritic ductile cast irons
M. Pedranz, V. Fontanari, C. Santus, F. Zanini, S. Carmignato, D. Lusuardi, F. Berto & M. Benedetti.......................103
7: TITANIUM ALLOYS I
Predicting fatigue crack initiation in milled aerospace grade Ti-6Al-4V parts using CPFEM
M. F. Arcidiacono, I. Violatos & S. Rahimi........................................................................................................................................115
Uncovering the role of building orientation and stress ratio on the fatigue behaviour of L-PBF Ti6Al4V miniaturised strut-like lattice specimens
S. Murchio, R. De Biasi, D. Maniglio, A. Rigatti, L. De Nart, V. Luchin & M. Benedetti.................................................................127
Cracking and damage mechanisms in nitrided Ti64 grade 5 alloy after high cycle fatigue
S. Stekovic, R. Boyd & L. Selegård....................................................................................................................................................140
8:
SURFACE CONDITIONS
Plenary Lecture: The effect of specimen machining processes on fatigue life of 42CrMo4+QT steel
J. Papuga, T. Vrbata, K. Trojan, A. Trefil, A. Zabala & V. Mára......................................................................................................155
Stability of compressive residual stresses in austempered ductile iron (ADI) under cyclic loading U. Hähnel, E. Müller & P. Hübner....................................................................................................................................................168
Impact of laser shock peening on fatigue strength of additively manufactured AlSi10Mg M. Matušů, O. Stránský, J. Šimota, L. Džuberová, J. Rosenthal, J. Papuga & L. Beránek...............................................................181
9:
HIGH TEMPERATURE
Consideration of elastoplasticity and viscoplasticity during thermomechanical fatigue simulations of a pipe bend using the FEMimplemented Prandtl operator approach
D. Šeruga, M. Nagode, J. Klemenc & S. Oman................................................................................................................................194
10: DESIGN
Plenary Lecture: Scale-bridging fatigue assessment of steels – from production to performance N. Baak, K. Donnerbauer, A. Kalenborn, H. Kanagarajah, L. Lücker, L. Lingnau, J. L. Otto, J. Rozo Vasquez, S. Strodick & F. Walther...........................................................................................................................................................................................205
Fatigue design of cast aluminium passenger car wheels with respect to the transfer of cyclic material properties
M. Hell 217
Finite element analysis of the MAGEC spinal rod under compressive and shear loading conditions
T. S. Mosley, M. Birkett, T. J. Joyce & F. Farhad 229
12: SUPERALLOYS I
Phase angle effects on thermo-mechanical fatigue (TMF) in a single crystal nickel superalloy
A. Gonzalez Garcia, J. Jones, R. Lancaster, M. Whittaker, S. John & J. Mason-Flucke..................................................................241
Coupling effects of temperature and fatigue, creep-fatigue interaction and thermo-mechanical loading conditions on crack growth and dominant failure mechanisms of a nickel-based alloy V. Shlyannikov, A. Shanyavskiy, A. Sulamanidze & D. Kosov............................................................................................................253
13: NON-METALLIC
MATERIALS
Crack growth in a piezoelectric ceramic induced by a cyclic electric field K. Hockauf, F. Poschmann & R. Pleul................................................................................................................................................265
High- and low-cycle tensile fatigue of all-carbon hybrid quasi-isotropic laminate V. Carvelli, S. B. Sapozhnikov, S. V. Lomov & Y. Swolfs....................................................................................................................276
Mean stress correction for carbon fibre reinforced polymer composites under fatigue loading Z. Lu...............................................................................................
Fracture and fatigue characterisation of the shot-earth 772
A. Zanichelli, A. Carpinteri, C. Ronchei, S. Scorza & S. Vantadori..................................................................................................293
Investigations on experimental fatigue life and damage of designed hybrid composite laminates with negative and positive Poisson’s ratio
H. Hosseini-Toudeshky, M. Tashayyoee, A. Navaei, J. Nafar Dastgerdi & S. Esmaeili....................................................................303
14: VARIABLE AMPLITUDE
Advanced concepts on fatigue and fatigue-crack growth of metallic materials
J. C. Newman Jr.................................................................................................................................................................................315
Plastic CTOD as fatigue crack growth characterising parameter under variable amplitude loading by using DIC G. L. Gómez-Gonzales, A. Camacho-Reyes, J. M. Vasco-Olmo, F. A. Díaz, D. Neto & F. V. Antunes..............................................330
Machine learning based fatigue life prediction of metal components subjected to block loading K. Hectors, Q. Bouckaert, J. Plets & W. De Waele...........................................................................................................................337
15: WELDS I
Industry-oriented assessment of the fatigue life of thin-walled profile weldments used in the construction of bus bodies M. Kepka, R. Minich, M. Krizek & M. Kepka Jr...............................................................................................................................357
Influence factors on fatigue strength of arc-welded joints using ultra-high strength steel sheets and its improving methods
N. Yamaguchi, T. Shiozaki, Y. Tamai, Y. Ichikawa & K. Ogawa........................................................................................................367
16: CONTACT
Evaluation of non-proportional multi-axial stress states in drive-train components related to contacts J. Schanner, A. Hasse & L. Suchý......................................................................................................................................................
Fretting fatigue of shafts under varying contact pressure and creep slip conditions in bearing-shaft contacts D. Knabner, L. Suchý, S. Busch & A. Hasse......................................................................................................................................396
Influence of microstructure, stress gradient and defect size on the stability of the critical distance method for fretting crack nucleation
H. Lannay, S. Fouvry, B. Berthel & C. Glandiolle............................................................................................................................407
17: MULTI AXIAL
Cracking behaviour and lifetime predictability of P558 steel in annealed and cold deformed states under mixed complex loading T. Ngeru & S. Hanke 419
The critical distance concept to design notched 3d-printed metals against uniaxial/multiaxial fatigue
L. Susmel...........................................................................................................................................................................................428
Experimental and computational investigation of mixed mode fatigue crack propagation
B. Sheen, C. M. Davies & D. Nowell.................................................................................................................................................441
18: TITANIUM ALLOYS II
Influence of defect shape and position on the high cycle fatigue behaviour of additively manufactured TA6V alloy M. Bonneric, N. Saintier, D. El-Khoukhi & J. Bega..........................................................................................................................452
19: ENVIRONMENT I
In vitro short-time testing method for evaluating the long-time corrosion fatigue strength of biomedical magnesium alloys
N. Wegner, K. Donnerbauer, L. Hempel & F. Walther........................................................................................................................461
Effect of artificial corrosion on retardation of fatigue crack growth – assessment by local cyclic plasticity
H. Shibata, K. Satoh, R. Fincato & S. Tsutsumi.................................................................................................................................473
Experimental validation of a model for predicting the bending fatigue strength of corroded grey cast iron water pipes
E. John, J. Boxall, R. Collins, E. Bowman & L. Susmel................ 482
20: SIMULATION
Plenary Lecture: Predictions of crack growth rates, R-ratio effects and overload behaviour based on smooth specimen LCF test data and using a strip yield-type model
S. J. Williams, M. T. Whittaker & M. C. Hardy...................................................................................................................................494
An investigation of the RSE-M crack closure parameter F(R) on a large ferritic PWR component with negative R-ratio including welding residual stress
M. P. Nielsen......................................................................................................................................................................................506
Numerical approaches in the fatigue damage simulation in quasi-brittle materials
L. Ferreira Friedrich, A. Bordin Colpo, S. Vantadori, F. Soares & I. Iturrioz..................................................................................520
Proposal of a fatigue crack extension mode and its prediction method — damage accumulation mode fatigue crack propagation
S. Hamada, Y. Okawa & Y. Araki......................................................................................................................................................531
22:
ENVIRONMENT II
Defect-based assessment of mechanical and corrosive loads on the capability of light metal structures
N. Wegner, A. Koch & F. Walther.......................................................................................................................................................539
24: SUPERALLOYS II
Effects of microstructure and oxidation on fatigue crack initiation behaviour in a titanium aluminide alloy Y. Yamazaki, K. Okada & K. Yoshida................................................................................................................................................551
25: LIFING
Integration of physical and virtual tests for achieving high confidence in fatigue reliability of automotive battery systems A. Halfpenny, K. Tahera, B. Thumati & C. Wynn-Jones....................................................................................................................561
Frequency domain fatigue approach for sine swept loadings G. De Morais.....................................................................................................................................................................................575
Key issues with residual fatigue life estimation in steels, highly scattered and non-conservative thresholds, crack closure mechanisms, influencing factors, relevant material properties T. Vojtek, R. Kubíček, P. Pokorný, M. Jambor, L. Náhlík & P. Hutař................................................................................................
26: HYDROGEN
Plenary Lecture: Design, usage and safety aspects for tubular specimens for materials qualification with pressurised hydrogen K. Wackermann, F. Ebling, T. Michler, F. Schweize & H. Oesterlin..................................................................................................604
Correlation of fatigue behaviour in pressurised hydrogen and electrolytically supplied hydrogen S. Schönborn & A. Kansy...................................................................................................................................................................615
Effect of pressurised hydrogen on low cycle fatigue of Inconel 718: modelling and testing
F. Ebling, H. Oesterlin & K. Wackermann........................................................................................................................................629
27: MICROSTRUCTURAL INFLUENCES
Fatigue damage assessment of C45 samples via different experimental measurements and microstructural investigations
A. Saponaro, R. De Finis, G. Renna, P. Leo & R. Nobile..................................................................................................................637
28: ADDITIVE MANUFACTURING III
On the role of the internal and surface defects in the fatigue and structural integrity of additively manufactured 316L stainless steel J. Nafar Dastgerdi, O. Jaberi & H. Remes........................................................................................................................................649
29: WELDS II
Improved fatigue calculation of attachment welds in offshore wind structures using additive MK factor J. Taylor.............................................................................................................................................................................................659
Fatigue performance of modern submerged arc welds in 85mm grade S355 steel C. Johnston........................................................................................................................................................................................671
Impact of shot peening on the fatigue strength of arc-welded advanced high strength steel assemblies
A. Nabara, C. Mareau, F. Morel, M-R. Chini, R. Munier, P. Kusakin & M. L. Facchinetti...............................................................680
