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Low-cycle fatigue in roll-formed aerospace components – process-integrated simulation and experimental characterisation

The introduction of novel manufacturing technologies in the aerospace sector requires a deeper understanding of process–structure–property relationships, particularly with respect to the cyclic fatigue behavior of thin-walled structural elements. For sheet metal parts produced by forming and mechanical joining, established design rules and verification procedures to reliably account for cold work hardening, residual stresses, and local geometry effects on fatigue life are currently lacking.

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Description

This contribution investigates the low-cycle fatigue behavior of an aluminum structural component manufactured by robot-assisted roll forming. The cyclic material response is modeled using a nonlinear kinematic hardening approach according to Chaboche [1], with model parameters identified from experimental data. The fatigue life assessment is carried out on the basis of the Local Strain Approach [2], explicitly considering the process history. Therefore manufacturing effects are directly integrated into the fatigue life estimation up to crack initiation.

Experimental parameter identification and validation is performed through cyclic loading tests in combination with optical strain field measurements. The results reveal the interrelation between process parameters, local stress–strain states, and fatigue life. This enables a simulation-based, cross-process optimization of the component performance. Thus, the study contributes to the extension of fatigue design concepts for advanced, forming-based lightweight structures in aerospace applications.

Reference: LCF10-2026-030

Title: Low-cycle fatigue in roll-formed aerospace components – process-integrated simulation and experimental characterisation
Author(s): B. Spak, P. Hantschke, M. Kästner
DOI: 10.48447/LCF10-2026-030
Event: Tenth International Conference on Low Cycle Fatigue (LCF-10)
Year of publication: 2026
Publication type: conference paper (PDF)
Language: English
Keywords: Low-cycle fatigue,Light-weight structures,Local Strain Approach

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Author(s): L. Stampa, P. Grimm, J. K. Hufenbach, M. Zimmermann

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Influence of Hydrogen on the LCF Behavior of Quenched and Tempered AISI 4140 Steel

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Anisotropy and Local Property Evolution of WAAM 316L and 17-4PH During Low-Cycle Fatigue

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Editor(s): T. Beck, F. Szmytka

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LCF10 | Tenth International Conference on Low Cycle Fatigue

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Delamination of Ceramic Top Coat in Thermal Barrier Coatings Subjected to Thermo-Mechanical Fatigue Loading

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Author(s): T. Hayashibe, K. Sasaki, K. Ohguchi, K. Fukuchi, S. Honda, Y. Tsubota, W. Nagai, K. Ohsato, N. Shinya

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Neural-Network-Based Low Cycle Fatigue Life Estimation of Aluminum Alloys - Effect of Input Variables

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Author(s): M. Arai, Y. Yamazaki

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A study of small crack propagation behavior in a single crystal Ni based superalloy under TMF conditions

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