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Background: <p>Material testing under fatigue load has been crucial in mechanical design, ever since the first relevant failures due to fatigue load produced catastrophic outcomes. In particular, high-cycle fatigue loading is quite common for most mechanical components. However, high-cycle fatigue tests require the specimen to undergo hundreds of thousands of cycles before failure occurs. Therefore, cycling must be performed as quickly as possible.</p> Objective: <p>Consequently, image acquisition becomes challenging because it requires synchronization with the loading cycle, high-speed acquisition, dynamic sampling, and failure detection. The standard solution to these problems is to stop the testing periodically and perform image acquisition. However, this requires continuous monitoring by a skilled operator. This work proposes an innovative low-cost experimental setup that performs such measurements in-line – with no interruption of the test – and without human interaction.</p> Methods: <p>By continuously monitoring the load and displacement signals of the testing machine, it is possible, on the one hand, to accurately synchronize image acquisition with the loading cycle and, on the other hand, to estimate the damage history to dynamically adjust image sampling.</p> Results: <p>Experimental tests prove that the proposed methodology enables the acquisition of blur-free images without pausing the test and using a standard camera.</p> Conclusions: <p>The proposed experimental approach allows for fully automatic monitoring of high-cycle fatigue tests. The system can collect images and track damage evolution through the final stage of the test with no human interaction. By adding a few low-cost components to the experimental setup, the proposed approach avoids the use of stroboscopic lamps and/or high-speed cameras.</p>

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A Digital Image Correlation Approach for High-Cycles Fatigue Test

  • 期刊论文

  • 发表日期：

    2026年4月20日

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  • P. M. Santucci,
  • A. Baldi

摘要

Background:

Material testing under fatigue load has been crucial in mechanical design, ever since the first relevant failures due to fatigue load produced catastrophic outcomes. In particular, high-cycle fatigue loading is quite common for most mechanical components. However, high-cycle fatigue tests require the specimen to undergo hundreds of thousands of cycles before failure occurs. Therefore, cycling must be performed as quickly as possible.

Objective:

Consequently, image acquisition becomes challenging because it requires synchronization with the loading cycle, high-speed acquisition, dynamic sampling, and failure detection. The standard solution to these problems is to stop the testing periodically and perform image acquisition. However, this requires continuous monitoring by a skilled operator. This work proposes an innovative low-cost experimental setup that performs such measurements in-line – with no interruption of the test – and without human interaction.

Methods:

By continuously monitoring the load and displacement signals of the testing machine, it is possible, on the one hand, to accurately synchronize image acquisition with the loading cycle and, on the other hand, to estimate the damage history to dynamically adjust image sampling.

Results:

Experimental tests prove that the proposed methodology enables the acquisition of blur-free images without pausing the test and using a standard camera.

Conclusions:

The proposed experimental approach allows for fully automatic monitoring of high-cycle fatigue tests. The system can collect images and track damage evolution through the final stage of the test with no human interaction. By adding a few low-cost components to the experimental setup, the proposed approach avoids the use of stroboscopic lamps and/or high-speed cameras.