<p>Metal fatigue critically affects structural material qualification, yet fatigue datasets often remain fragmented across raw hysteresis files, spreadsheet summaries, processing records, and post-processed descriptors. This study develops a fatigue-specific relational database framework for traceable reliability analytics using an Integrated Computational Materials Engineering-compatible Process–Structure–Property–Performance (PSPP) architecture. The framework was demonstrated using an Al 6063 fatigue dataset comprising 85 sample-level records across 17 thermomechanical processing routes, supported by 159,967 cycle-level records. A Python-based ETL pipeline was implemented to standardize raw fatigue outputs, aggregate stabilized cyclic descriptors, enforce database integrity, and generate analysis-ready PSPP features. The dataset showed substantial processing-induced fatigue dispersion, with <i>N</i><sub><i>f</i></sub> ranging from 362 to 7599 cycles and CoV = 0.988. Route-family statistics revealed a clear fatigue-life hierarchy, with ECAP showing the highest mean fatigue life (6729 cycles), followed by DCT, HT, and AR conditions. Reliability analysis yielded a global Weibull shape parameter <i>β</i> = 1.223, scale parameter <i>η</i> = 2034.43 cycles, B10 life of 323.01 cycles, and bootstrap mean-life confidence interval of 1520.83-2306.27 cycles. PSPP analysis confirmed physically consistent relationships, including grain size versus log<sub>10</sub>(<i>N</i><sub><i>f</i></sub>) (<i>r </i>=  − 0.788) and d<sup>−1/2</sup> versus yield strength (<i>r </i>= 0.781). A compact Ridge model using four PSPP descriptors achieved Leave-One-Route-Out <i>R</i><sup>2</sup> = 0.580 and RMSE = 0.206 in log<sub>10</sub>(<i>N</i><sub><i>f</i></sub>), demonstrating interpretable route-aware modelling rather than standalone deployment prediction. The proposed framework enables reproducible fatigue data governance, probabilistic reliability interpretation, and ICME-aligned database intelligence for future materials qualification workflows.</p>

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Fatigue Data Infrastructure for Reliability Analytics: A Relational Database Framework for Traceable Fatigue Knowledge Integration

  • Sreearravind Mani,
  • Ramesh Kumar Subramanian

摘要

Metal fatigue critically affects structural material qualification, yet fatigue datasets often remain fragmented across raw hysteresis files, spreadsheet summaries, processing records, and post-processed descriptors. This study develops a fatigue-specific relational database framework for traceable reliability analytics using an Integrated Computational Materials Engineering-compatible Process–Structure–Property–Performance (PSPP) architecture. The framework was demonstrated using an Al 6063 fatigue dataset comprising 85 sample-level records across 17 thermomechanical processing routes, supported by 159,967 cycle-level records. A Python-based ETL pipeline was implemented to standardize raw fatigue outputs, aggregate stabilized cyclic descriptors, enforce database integrity, and generate analysis-ready PSPP features. The dataset showed substantial processing-induced fatigue dispersion, with Nf ranging from 362 to 7599 cycles and CoV = 0.988. Route-family statistics revealed a clear fatigue-life hierarchy, with ECAP showing the highest mean fatigue life (6729 cycles), followed by DCT, HT, and AR conditions. Reliability analysis yielded a global Weibull shape parameter β = 1.223, scale parameter η = 2034.43 cycles, B10 life of 323.01 cycles, and bootstrap mean-life confidence interval of 1520.83-2306.27 cycles. PSPP analysis confirmed physically consistent relationships, including grain size versus log10(Nf) (r =  − 0.788) and d−1/2 versus yield strength (r = 0.781). A compact Ridge model using four PSPP descriptors achieved Leave-One-Route-Out R2 = 0.580 and RMSE = 0.206 in log10(Nf), demonstrating interpretable route-aware modelling rather than standalone deployment prediction. The proposed framework enables reproducible fatigue data governance, probabilistic reliability interpretation, and ICME-aligned database intelligence for future materials qualification workflows.