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<p>The objective of this work was to develop a generalized fatigue assessment approach for steel castings for a range of casting quality details. This work examined the effect of quality details on the fatigue performance of steel castings using linear elastic fracture mechanics (LEFM) analysis. In particular, this research effort focused on addressing design guidelines in the casting industry, as current fatigue assessment approaches can be too conservative leading to overdesigned parts and usage of computationally expensive methods. The LEFM approach used in this study was shown to capture experimental data in the high cycle fatigue regime using Murakami’s effective area method for quality details estimation. A main outcome of this study found that the minimum indication size detected using phased array ultrasonic testing, an industry accepted nondestructive evaluation technique, correlated with the proposed lower limits of the LEFM fatigue design approach.</p>

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Development of a Generalized Fatigue Assessment Approach for Steel Castings

  • 期刊论文

  • 发表日期：

    2025年4月14日

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  • Matthew Batson,
  • David Eisenmann,
  • Pruthul Kokkada Ravindranath,
  • David Jack,
  • P. G. Allison,
  • J. B. Jordon

摘要

The objective of this work was to develop a generalized fatigue assessment approach for steel castings for a range of casting quality details. This work examined the effect of quality details on the fatigue performance of steel castings using linear elastic fracture mechanics (LEFM) analysis. In particular, this research effort focused on addressing design guidelines in the casting industry, as current fatigue assessment approaches can be too conservative leading to overdesigned parts and usage of computationally expensive methods. The LEFM approach used in this study was shown to capture experimental data in the high cycle fatigue regime using Murakami’s effective area method for quality details estimation. A main outcome of this study found that the minimum indication size detected using phased array ultrasonic testing, an industry accepted nondestructive evaluation technique, correlated with the proposed lower limits of the LEFM fatigue design approach.