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Effect of welding spots on the stress intensity and crack propagation angle under plain fretting and fretting fatigue with flat-flat contact

The failure mechanisms in fretting fatigue are due to micro slip movement under contact pressure. This causes characteristic tribological damage to the surface, resulting in cracks, which can lead to a significant reduction in the fatigue strength of components in contact compared to plain fatigue. To investigate the effect on the strength and crack initiation and propagation mechanisms, the use of a fretting pad test rig as a laboratory model has already been established, in which actively controlled slip and contact pressure can be set independently of the external bulk load. The failure of the flat tensile specimen is primarily preceded by crack formation and propagation from the inside of the contact surface (Fig. 1), influenced by the multiaxial stress state, which implies a…

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The failure mechanisms in fretting fatigue are due to micro slip movement under contact pressure. This causes characteristic tribological damage to the surface, resulting in cracks, which can lead to a significant reduction in the fatigue strength of components in contact compared to plain fatigue. To investigate the effect on the strength and crack initiation and propagation mechanisms, the use of a fretting pad test rig as a laboratory model has already been established, in which actively controlled slip and contact pressure can be set independently of the external bulk load. The failure of the flat tensile specimen is primarily preceded by crack formation and propagation from the inside of the contact surface (Fig. 1), influenced by the multiaxial stress state, which implies a tribologically induced failure. The simulative model structure and frictional contact in previous research projects [1] and also in the literature [2] is primarily based on a Coulomb friction contact with a global coefficient of friction. In the experimental tests, however, areas close to the crack initiation sites were also found that could be interpreted as welding spots.

The subject of the investigation is now to perform a simulative comparison of the integrated contact conditions and their effects on the progress of a crack. The basis for this is given within the field of fracture mechanics by the two-threshold model according to Vasudevan et al. [3] combined with a statically introduced crack observed in experiments (Fig. 2) and the integration of the elastic-plastic material behaviour of the experimental reference material spheroidal cast iron GJS-700. Due to the non-proportional loading conditions and multiaxial stresses, an extended criterion for evaluating the equivalent stress intensity factor is applied using crack propagation angles calculated according to Hourlier et al. [4] and Giner et al. [5] comparatively after investigating several other criteria. With these simulative boundary conditions, the previously assumed global coefficient of friction in the Coulomb friction model only shows a sufficiently high stress intensity factor for propagation when the chosen coefficient of friction is above the range revealed by friction tests. In contrast, the introduced locally welded area on the weaker crack flank close to the crack initiation position leads on the one hand to a crack propagation angle that is quantitatively comparable with experimental data and on the other hand indicates crack propagation according to the two-threshold concept. Furthermore, with an additionally integrated bulk force, the crack tip stresses are increased while maintaining the correct crack propagation angle. This setup applied on a longer crack like it was found in run-out specimens leads to smaller crack tip loading indicating crack arrest as it is proven with the run-out samples. Thus, it is simulatively proven that local welding spots can cause and enhance crack growth for short cracks under fretting fatigue and plain fretting conditions, reflected by higher ∆Keq and Keq,max values. In addition, despite the integrated welding spots, crack arrest is indicated under pure fretting and fretting fatigue loading for longer cracks.

Artikelnummer
ICMFF14-2025-16

Titel
Effect of welding spots on the stress intensity and crack propagation angle under plain fretting and fretting fatigue with flat-flat contact
Autor(en)
M. Müller, D. Knabner, L. Suchy, A. Hasse
DOI
10.48447/ICMFF14-2025-16
Veranstaltung
14. International Conference on Multiaxial Fatigue and Fracture 2025
Jahr der Veröffentlichung
2025
Publikationsart
Tagungsmanuskript (PDF)
Sprache
Englisch
Stichwörter
fretting fatigue,crack propagation,FE-simulation,welding spots,stress intensity factor

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14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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Simulation of crack propagation in ductile materials under non-proportional loading conditions. Part II: Phase field modelling of crack propagation
Simulation of crack propagation in ductile materials under non-proportional loading conditions. Part II: Phase field modelling of crack propagation
A. Gibb, A. Tsakmakis, M. Vormwald
10.48447/ICMFF14-2025-59
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Plasticity,Phase Field,Multi-axial,Fatigue,Damage 
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Simulation of crack propagation in ductile materials under non-proportional loading conditions. Part II: Phase field modelling of crack propagation
A. Gibb, A. Tsakmakis, M. Vormwald
10.48447/ICMFF14-2025-59
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Plasticity,Phase Field,Multi-axial,Fatigue,Damage
Preis 25,00 €
Nur online erhältlich Neu
Fatigue strength assessment of different materials under variable amplitude loadings with the Findley damage parameter
Autor(en): C. Fällgren, M. Vormwald
10.48447/ICMFF14-2025-01
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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Fatigue strength assessment of different materials under variable amplitude loadings with the Findley damage parameter
Fatigue strength assessment of different materials under variable amplitude loadings with the Findley damage parameter
C. Fällgren, M. Vormwald
10.48447/ICMFF14-2025-01
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Fatigue strength assessment of different materials under variable amplitude loadings with the Findley damage parameter
C. Fällgren, M. Vormwald
10.48447/ICMFF14-2025-01
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Multiaxial fatigue,Findley parameter,critical plane method,variable amplitude loading,FKM-guideline
Preis 25,00 €
Nur online erhältlich Neu
Crack Initiation Life Estimate for Notched Specimens of SUS304 and Mod.9Cr-1Mo Steels under Nonproportional Cyclic Loading
Autor(en): M. Sakane
10.48447/ICMFF14-2025-43
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Low cycle fatigue,notch,nonproportional loading,crack initiation life,life estimate 
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Crack Initiation Life Estimate for Notched Specimens of SUS304 and Mod.9Cr-1Mo Steels under Nonproportional Cyclic Loading
Crack Initiation Life Estimate for Notched Specimens of SUS304 and Mod.9Cr-1Mo Steels under Nonproportional Cyclic Loading
M. Sakane
10.48447/ICMFF14-2025-43
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Crack Initiation Life Estimate for Notched Specimens of SUS304 and Mod.9Cr-1Mo Steels under Nonproportional Cyclic Loading
M. Sakane
10.48447/ICMFF14-2025-43
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Low cycle fatigue,notch,nonproportional loading,crack initiation life,life estimate
Preis 25,00 €
Nur online erhältlich Neu
Application of Multiaxial Fatigue Criteria for Fretting Fatigue Analysis and Life Predictions
Autor(en): S. Ghadar, A. Fatemi, N. Phan
10.48447/ICMFF14-2025-20
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Multiaxial Fatigue,Fretting Fatigue,Life Prediction 
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Application of Multiaxial Fatigue Criteria for Fretting Fatigue Analysis and Life Predictions
Application of Multiaxial Fatigue Criteria for Fretting Fatigue Analysis and Life Predictions
S. Ghadar, A. Fatemi, N. Phan
10.48447/ICMFF14-2025-20
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Multiaxial Fatigue,Fretting Fatigue,Life Prediction 
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Application of Multiaxial Fatigue Criteria for Fretting Fatigue Analysis and Life Predictions
S. Ghadar, A. Fatemi, N. Phan
10.48447/ICMFF14-2025-20
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Multiaxial Fatigue,Fretting Fatigue,Life Prediction
Preis 25,00 €
Nur online erhältlich Neu
Fatigue assessment of additively manufactured V-notched Ti6Al4V engineering components under multiaxial stress state in high-cycle regime: a novel approach
Autor(en): S. Vantadori, A. Carpinteri, C. Ronchei, D. Scorza, A. Zanichelli
10.48447/ICMFF14-2025-55
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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Fatigue assessment of additively manufactured V-notched Ti6Al4V engineering components under multiaxial stress state in high-cycle regime: a novel approach
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S. Vantadori, A. Carpinteri, C. Ronchei, D. Scorza, A. Zanichelli
10.48447/ICMFF14-2025-55
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Fatigue assessment of additively manufactured V-notched Ti6Al4V engineering components under multiaxial stress state in high-cycle regime: a novel approach
S. Vantadori, A. Carpinteri, C. Ronchei, D. Scorza, A. Zanichelli
10.48447/ICMFF14-2025-55
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
critical distance,porosity,surface roughness,Ti6Al4V,V-notch
Preis 25,00 €
Nur online erhältlich Neu
The Use of Polar Damage Sum Concept for Calculating Mean Stress Effect in Multiaxial Fatigue Loading Conditions
Autor(en): J. Albinmousa, A. Alhammali, M. Ismail
10.48447/ICMFF14-2025-29
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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The Use of Polar Damage Sum Concept for Calculating Mean Stress Effect in Multiaxial Fatigue Loading Conditions
The Use of Polar Damage Sum Concept for Calculating Mean Stress Effect in Multiaxial Fatigue Loading Conditions
J. Albinmousa, A. Alhammali, M. Ismail
10.48447/ICMFF14-2025-29
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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The Use of Polar Damage Sum Concept for Calculating Mean Stress Effect in Multiaxial Fatigue Loading Conditions
J. Albinmousa, A. Alhammali, M. Ismail
10.48447/ICMFF14-2025-29
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Fatigue damage,multiaxial,Mean stress,Polar damage sum concept,critical plane concept
Preis 25,00 €
Nur online erhältlich Neu
Evaluation of multi-axial stresses using the FKM guideline - status quo and how it can be improved
Autor(en): M. Wächter, R. Wuthenow, C. Fällgren, H.-T. Beier, M. Obermayr, R. Rennert, M. Vormwald, A. Esderts
10.48447/ICMFF14-2025-62
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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10.48447/ICMFF14-2025-62
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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10.48447/ICMFF14-2025-62
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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Preis 25,00 €
Nur online erhältlich Neu
Data-Driven Approach to Statistical-Based Fatigue Predictions of the Findley Criterion
Autor(en): A. Trapp, K. Rother
10.48447/ICMFF14-2025-47
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Non-Proportional Stresses,Random Vibration Loading,Data-Driven Approach,Non-Stationary Loading,Modal Approach 
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Data-Driven Approach to Statistical-Based Fatigue Predictions of the Findley Criterion
Data-Driven Approach to Statistical-Based Fatigue Predictions of the Findley Criterion
A. Trapp, K. Rother
10.48447/ICMFF14-2025-47
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Data-Driven Approach to Statistical-Based Fatigue Predictions of the Findley Criterion
A. Trapp, K. Rother
10.48447/ICMFF14-2025-47
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Non-Proportional Stresses,Random Vibration Loading,Data-Driven Approach,Non-Stationary Loading,Modal Approach
Preis 25,00 €
Nur online erhältlich Neu
Unifying multiaxial fatigue life prediction of welded joints by considering support effects
Autor(en): N. M. Bauer, A. Wöhle, J. Baumgartner
10.48447/ICMFF14-2025-33
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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Unifying multiaxial fatigue life prediction of welded joints by considering support effects
N. M. Bauer, A. Wöhle, J. Baumgartner
10.48447/ICMFF14-2025-33
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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N. M. Bauer, A. Wöhle, J. Baumgartner
10.48447/ICMFF14-2025-33
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
multiaxial fatigue,stress averaging,welded joints,support effect,stress gradient
Preis 25,00 €
Nur online erhältlich Neu
Fatigue assessment of structural components through the Effective Critical Plane approach: methodology and applications
Autor(en): A. Chiocca, F. Frendo, M. Sgamma
10.48447/ICMFF14-2025-25
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
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Fatigue assessment of structural components through the Effective Critical Plane approach: methodology and applications
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A. Chiocca, F. Frendo, M. Sgamma
10.48447/ICMFF14-2025-25
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Fatigue assessment of structural components through the Effective Critical Plane approach: methodology and applications
A. Chiocca, F. Frendo, M. Sgamma
10.48447/ICMFF14-2025-25
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Structural integrity,Critical plane methods,Multiaxial loading,Fatigue assessment,Effective Critical Plane approach
Preis 25,00 €
Nur online erhältlich Neu
Multiaxial Fatigue Life Prediction based on Complex Invariants Compared to Critical Cutting Plane Approaches
Autor(en): W. C. Hübsch, C. Gaier
10.48447/ICMFF14-2025-11
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Equivalent stress,Multiaxiality,fatigue analysis 
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Multiaxial Fatigue Life Prediction based on Complex Invariants Compared to Critical Cutting Plane Approaches
Multiaxial Fatigue Life Prediction based on Complex Invariants Compared to Critical Cutting Plane Approaches
W. C. Hübsch, C. Gaier
10.48447/ICMFF14-2025-11
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Equivalent stress,Multiaxiality,fatigue analysis 
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Multiaxial Fatigue Life Prediction based on Complex Invariants Compared to Critical Cutting Plane Approaches
W. C. Hübsch, C. Gaier
10.48447/ICMFF14-2025-11
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Equivalent stress,Multiaxiality,fatigue analysis
Preis 25,00 €
Nur online erhältlich Neu
Multiaxial Fatigue of Weldments: Experiments and Modeling
Autor(en): A. Razi, A. Fatemi
10.48447/ICMFF14-2025-21
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Fatigue life prediction, Welded joint, Multiaxial loading, Variable amplitude loading, Fracture mechanics, Weld fatigue design codes 
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Multiaxial Fatigue of Weldments: Experiments and Modeling
Multiaxial Fatigue of Weldments: Experiments and Modeling
A. Razi, A. Fatemi
10.48447/ICMFF14-2025-21
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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Multiaxial Fatigue of Weldments: Experiments and Modeling
A. Razi, A. Fatemi
10.48447/ICMFF14-2025-21
14. International Conference on Multiaxial Fatigue and Fracture 2025
2025
Tagungsmanuskript (PDF)
Englisch
Fatigue life prediction, Welded joint, Multiaxial loading, Variable amplitude loading, Fracture mechanics, Weld fatigue design codes
Preis 25,00 €
Nur online erhältlich Neu