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Destructive and nondestructive remaining fatigue life prediction methods of metals: a review

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Abstract

Metals’ remaining fatigue life (RFL) forecast is considered to be an overly complicated process among engineers in practical applications, especially since a fast and acceptable level of safety operation and trust assessment are needed to avoid fatigue risks in worksites. The internal damage that the material suffers under fatigue stress results in invisible changes in the microstructure, which may lead to its failure below the intended design life of the material. Therefore, predictive calculations of RFL are very important for personnel safety and design quality. Here, the RFL prediction models and material-dependent characteristic components are reviewed via two approaches: the destructive (DT) and nondestructive (NDT) methods. Typical measurements and data associated with their relationships, such as stress, strain and effective contact at different stages of fatigue failure were explored. Moreover, the effectiveness of the DT and NDT evaluation methods was compared to obtain the information and description of the material fatigue response. Subsequently, the best models were selected.

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Abbreviations

a :

Crack length (m)

P :

Baseline likelihood

σ i :

Stress level (N/m2)

S c :

The crack area is determined from the binary image

σ u :

Ultimate tensile stress (N/m2)

S t :

The total area of the view

n i :

Cyclic number of the respective stress level

A, B, α :

Constants obtained under different strain amplitude cycles

N i :

Fatigue life corresponds to the current stress level

ΔK :

Stress intensity factor range (MPa \(\sqrt {} {\rm{m}}\))

da/dN :

Crack growth rate (m/cycle)

W :

Specimen width

D :

Damage parameter (damage level)

m NF :

Mean value of variation for fatigue failure cycles

C, m :

Parameters for damage growth

v NF :

Coefficient of variation for fatigue failure cycles

N :

Number of fatigue cycles

m Nn :

Mean value of variation for the cycles of the applied load

N f :

Total number of fatigue cycles to failure

v Nn :

Coefficient of variation for the cycles of the applied load

S :

The ratio of the crack area to the specific area

R θ :

Change in metal temperature per cycle (C°/cycle)

R r :

Thermal response of metal

P f :

Corresponding to failure probability

β :

Probability of failure

β :

Nonlinearity parameter

A 1 :

Fundamental displacement signals

β e :

Elastic nonlinearity parameter

A 2 :

Second-harmonic displacement signals

A e3 :

Huang coefficient of the third order

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Acknowledgments

The authors would like to state that this study was conducted without any external funding or financial support. Despite this, the authors would like to extend their sincere appreciation to their supervisor from The Energy University for providing invaluable guidance and expertise throughout the research project. Their support was instrumental in the success of this study, and the authors are grateful for their contributions.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, University Tenaga Nasional, Kajang, Malaysia

    Madyan Abduljabbar Marir, Ewe Lay Sheng & Mohd Rashdan Isa

  2. General Company for Ports of Iraq, Ministry of Transportation, Basra, Iraq

    Madyan Abduljabbar Marir

  3. Materials Engineering Department, University of Basra, Basra, Iraq

    Imad Obaid Bachi

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  1. Madyan Abduljabbar Marir
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  2. Ewe Lay Sheng
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  3. Mohd Rashdan Isa
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Correspondence to Madyan Abduljabbar Marir.

Additional information

Madyan Abduljabbar Marir was born in Basrah, Iraq. He is a research doctoral student at the University of Tenaga Nasional, Kajang, Malaysia. He holds a master’s degree in mechanical engineering from the University of Basra (2017) and a bachelor’s degree from the Naval College, Marine Engineering Branch, Iraq (2002). He works as a senior chief marine engineer at the General Company for Ports of Iraq. His research interests are nondestructive stress investigation, fatigue analysis and solid mechanics.

Lay Sheng Ewe was born in Penang Island, Malaysia. She received her Ph.D. degree in Pure Physics from the National University of Malaysia in 2008. She is currently an Associate Professor at the Energy University, Putrajaya Campus, Malaysia. Her research interests include material science, superconductor and magnetoresistance (MR). She received her Professional Technologist from the Malaysia Board of Technologists (MBOT) in the year 2020.

Mohd Rashdan Isa was born in Kelantan, Malaysia. He received his Ph.D. degree in Engineering from The Energy University in 2020. His background was in Mechanical Engineering from the University of Applied Science Mannheim in Germany. He is currently a Senior Lecturer with The Energy University and Principal Researcher under the Institute of Sustainable Engineering, Putrajaya Campus, Malaysia. His research is in Applied Mechanics and Renewable Engineering. He received his Professional Technologist from the Malaysia Board of Technologists (MBOT) in the year 2022.

Imad O. Bachi is a Lecturer in the Materials Engineering Department, Basrah University, Basra, Iraq. He received his Ph.D. in Mechanical Engineering from Basrah University and HUST in China. His research interests include nanobeam, vibration, ANSYS, ADINA, neural fuzzy control and fractures.

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Marir, M.A., Sheng, E.L., Isa, M.R. et al. Destructive and nondestructive remaining fatigue life prediction methods of metals: a review. J Mech Sci Technol 37, 3999–4015 (2023). https://doi.org/10.1007/s12206-023-0716-y

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  • DOI: https://doi.org/10.1007/s12206-023-0716-y

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