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In this study, forged EA4T steel specimens are subjected to three quenching temperatures of 800, 860, and 900 °C. Microhardness tester, laser scanning confocal microscopy, and scanning electron microscopy (SEM) are employed to measure microhardness, metallographic structure, and fatigue fracture characteristics, respectively. Heat treatment is found to be necessary to improve mechanical properties and fatigue behavior of initial forgings, and the effects of microstructure and defect are significant. Hence, considering variations of grain types and roughness between the initial forgings and heat-treated specimens, the fatigue property with defects are modified for roughness-affected axles by an improved KT diagram. The results indicate that the samples quenching at 860 °C achieved better fatigue performance due to the presence of fine polygonal ferrite (PF), bainite, as well as martensite. The fatigue life prediction error for the roughness-affected axle is between 16 and 18%. All of the fracture mechanism, grain size, and dislocation slip with different quenching temperatures affecting the fatigue performance are analyzed. Because the volume fraction of the martensite and bainite is significantly higher reaching 57.48% and more refined grains are obtained, the dislocation slip to the surface is delayed at the quenching temperature of 860 °C. Thus, the fatigue behavior is superior. Moreover, the yield strength increased by 22% compared to that of the initial forgings. Studies on the effect of the heat treatment process on fatigue behavior of EA4T steel contribute with a practical reference to the engineering application of high-speed rail axles.

Ceramic coatings were prepared by plasma electrolytic oxidation (PEO) on four different surface roughness’ of Ti-6Al-4V alloys. The effects of substrate roughness on the microstructure and fatigue behavior were investigated. Microstructural characterization was carried out by scanning electron microscopy (SEM) and a laser scanning confocal microscope. In addition, an X-ray diffractometer (XRD) and a U-X360 stress meter were used to analyze the phase composition and residual stress properties of the coatings. The microstructure of coatings revealed the growth mechanism of the coatings. The larger and deeper grooves of the substrate promoted the nucleation and growth of the PEO coating, but the defects (cracks and pores) of the oxide layer became more serious. The fatigue test indicated a significant influence of substrate roughness on the fatigue life under low cyclic stress. The fatigue damage of PEO coatings decreases as the surface roughness of substrates decreases because of the synergistic effect of the coating surface defects and coating/substrate interface roughness. Substrate roughness influences the quality and fatigue performance of the oxide layer.

Two types of aluminum (Al) alloys, namely 2024-T3 and 7075-T6, were treated by micro-arc oxidation (MAO). Microstructure of as-fabricated ceramic coatings was investigated. Furthermore, the effect of MAO time on fatigue life of the coated samples with thin coating was systematically explored. Morphologies of the coating, second phase particles, and distribution of copper (Cu) and Zinc (Zn) in the coating were observed by scanning electron microscopy, confocal laser scanning microscopy, and energy dispersive spectrometry. Residual stress and phase compositions were analyzed by X-ray diffraction. More Cu in 2024-T3 Al alloy promoted formation of the coating; however, surface porosity of the coating was high. Residual stress induced in the coating deposited on AA2024 was compressive in nature. In contrast, the residual stress in the coating prepared on AA7075 was tensile due to the high content of Zn in the substrate. The results of fatigue test showed that fatigue life of the coated AA2024 increased; however, the MAO treatment was detrimental to fatigue performance of the AA7075 compared to uncoated samples. With prolonging oxidation time, the fatigue life of the coated samples first increased and then decreased. The changes of fatigue life were attributed to the residual stress, coating defects including micro-pores and micro-cracks, and second phase particles in the Al alloy substrate.

Laser metal deposition (LMD) is a common manufacturing technique of laser additive manufacturing (LAM) which belongs to coaxial powder feeding method. The LMDed SS304 specimens are fabricated by the same combination of the process parameters so that they have the similar properties. The microstructure is similar to that of the selective laser melted (SLMed) specimen. The grain sizes of the LMDed specimen are compared with those of the specimens manufactured by the traditional method and SLM. Through the calculation of Ni and Cr equivalents in the LMDed SS304 specimen and the analytical results of electron backscattered diffraction (EBSD) and energy dispersive spectroscope (EDS), the phase compositions of the LMDed SS304 specimen are evaluated. The hardness of the LMDed specimen is compared with that of the conventionally manufactured wrought SS304 and SLMed specimens. And due to the differences of the grain size and phase composition on the different directions, the hardness of the LMDed specimen is anisotropic. The static tensile properties (ultimate tensile strength (UTS), yield strength (σ0.2) and elongation (EL)) and fatigue strength (FS) of the LMDed specimen are compared with those of the specimens made by the traditional method and SLM. The S N curve is established by the multiple experiments. Scanning electron microscopy (SEM) is applied to observe the fracture morphology of the static tension and tension-compression fatigue tests. And EDS is applied to analyze the chemical compositions of the particles on the fracture surface. As expected, LMD has the higher static tensile properties and fatigue strength than those of the specimen manufactured by the traditional method.

Due to the stratified nature of the manufacturing process, material extrusion (ME) parts have lower mechanical properties than those fabricated by traditional technology. This is one of the most significant defects hindering the development and application of this rapid prototyping technique. In this paper, vibration was applied to the ME process by using piezoelectric ceramics for the first time to improve the mechanical properties of the built parts. The vibrating ME equipment was established, and the specimens processed in different build directions were individually fabricated without applied vibration and with different applied vibrations. To quantify the effect of applied vibration on their mechanical properties and to summarize the influencing rule, a series of experimental tests were then performed on these specimens. A comparison between the testing results shows that the tensile strength and plasticity of the specimens, especially those processed in the Z direction, can be obviously improved by applied vibration. The orthogonal anisotropy is decreased obviously. The improvement becomes greater with increasing vibration frequency or amplitude. From the microscopic point of view, it can be seen that applied vibration can reduce the part’s defects of porosity and inclusion as well as separation between layers and, thereby, improve the bonding strength.

Ceramic coatings were produced on AA7075-T6 alloy by micro-arc oxidation (MAO). The MAO treatment was performed at different duty cycles (8, 10, 15, and 20%). Effects of duty cycle on microstructure and fatigue behavior of the coated samples were investigated. Surface features and cross-section morphology, and fatigue fracture were observed by SEM and laser microscope. Phase structure and residual stress in the coatings were analyzed by X-ray diffraction. The nature and relaxation mechanism of the residual stress were revealed. Finally, the influence of the residual stress relaxation on the fatigue life at high and low cyclic stresses was explored.

This study carried out the fatigue tests of selective laser melting (SLM) 304L austenitic stainless steel (SS) made by different scanning speeds. The purpose is to deeply understand the microstructure, fatigue failure process and fatigue failure mechanism of SLMed 304L SS. For this purpose, the microstructure, surface roughness and porosity were tested by field emission scanning electron microscope (FESEM) and electron backscatter diffraction (EBSD), while the residual stress was obtained by μ-X360 residual stress analyzer. In addition, the fatigue failure process of SLMed 304L SS was in-situ monitored through acoustic emission (AE) technique and thermal imager. The results show that SLMed 304L SS has excellent fatigue performance. The ‘critical’ value is defined to distinguish the critical influence of surface roughness and porosity. In addition, the temperature rise caused by the stored energy deriving from the active dislocation motions is affected by the loading direction and scanning direction by regulating the dislocation motions during fatigue testing.

An EA4T steel billet was forged at the different initial forging temperatures (1050, 1150, and 1250 °C). The microstructure and fatigue fracture of forged samples were observed by laser scanning confocal microscopy and scanning electron microscopy, respectively. The fatigue performance of samples forged at an initial forging temperature of 1250 °C was better owing to the presence of fine polygonal ferrite (PF). The difference in yield strength and ultimate tensile strength can be attributed to the average grain size of PF and acicular ferrite (AF) content, respectively. A relationship between the tensile strength and fatigue limit of EA4T steel is proposed. The mechanism of grain size and dislocation slip affecting the fatigue property was elucidated. Because the fine PF grains delayed the dislocations moving to the surface and inhibited the formation of intrusion and extrusion, premature cracks were not easily produced. This contributed to excellent fatigue behavior. Additionally, the pearlite colonies and fine PF delayed the crack growth rate and changed the crack propagation path. Studies on fatigue behavior provided a foundation for quality control and engineering application of EA4T steel.

This study investigated the effect of countersunk hole depths (0.65, 0.90, and 1.20 mm) on the fatigue performance of the riveted AA2024-T3 alloy. The fatigue fracture of the samples was observed by scanning electron microscopy. The strain at the countersink hole was analyzed by finite element (FE) method. The stress intensity and stress concentration factor of the countersunk holes were calculated. The rationality of the FE analysis and theoretical calculation was verified by measuring the strain near the countersunk holes. The high cycle fatigue life of the samples with a countersunk depth of 1.20 mm was far less than the other samples. In contrast, the low cycle fatigue life changed insignificantly.

Medium-carbon steel is commonly used for the rail, wire ropes, tire cord, cold heading, forging steels, cold finished steel bars, machinable steel and so on. Its fatigue behavior analysis and fatigue life estimation play an important role in the machinery industry. In this paper, the estimation of fatigue life of medium-carbon steel with different surface roughness using established S-N and P-S-N curves is presented. To estimate the fatigue life, the effect of the average surface roughness on the fatigue life of medium-carbon steel has been investigated using 75 fatigue tests in three groups with average surface roughness (Ra): 0.4μm, 0.8μm, and 1.6μm respectively. S-N curves and P-S-N curves have been established based on the fatigue tests. The fatigue life of medium-carbon steel is then estimated based on Tanaka-Mura crack initiation life model, the crack propagation life model using Paris law, and material constants of the S-N curves. 6 more fatigue tests have been conducted to validate the presented fatigue life estimation formulation. The experimental results have shown that the presented model could estimate well the mean fatigue life of medium-carbon steel with different surface roughness