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<p>This study investigates the severe reduction in fatigue life of 7075-T6511 aluminum alloy caused by small, shallow surface dents (≤ 1 mm in diameter, ~ 50 μm in depth) produced by compressive contact of hard objects. A comprehensive experimental program was conducted on smooth and dented specimens under both axial and torsional loadings, with the latter systematically examined for indentation-induced defects for the first time. The tests revealed pronounced reductions in fatigue life, particularly at lower loading amplitudes. To address this problem, a predictive methodology was developed that integrates fatigue characterization of smooth specimens with elastoplastic finite element simulations to quantify residual stress fields near dents. Fatigue life predictions were performed using the Zhao–Jiang model, which proved effective in identifying critical failure zones, with most estimates falling within a conservative threefold error margin. The proposed framework balances predictive reliability with computational efficiency, providing a practical tool for defect-sensitive fatigue assessment. By combining experimental evidence with validated modeling, the study advances the understanding of localized residual stress and stress concentration effects on fatigue degradation in high-strength aluminum alloys.</p>

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Severe fatigue life reduction in 7075-T6511 aluminum alloy caused by shallow indentation defects: experimental investigation and predictive modeling

  • 期刊论文

  • 发表日期：

    2025年11月25日

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  • Natalia Gonçalves Torres,
  • Jorge Luiz de Almeida Ferreira,
  • Edgar Nobuo Mamiya

摘要

This study investigates the severe reduction in fatigue life of 7075-T6511 aluminum alloy caused by small, shallow surface dents (≤ 1 mm in diameter, ~ 50 μm in depth) produced by compressive contact of hard objects. A comprehensive experimental program was conducted on smooth and dented specimens under both axial and torsional loadings, with the latter systematically examined for indentation-induced defects for the first time. The tests revealed pronounced reductions in fatigue life, particularly at lower loading amplitudes. To address this problem, a predictive methodology was developed that integrates fatigue characterization of smooth specimens with elastoplastic finite element simulations to quantify residual stress fields near dents. Fatigue life predictions were performed using the Zhao–Jiang model, which proved effective in identifying critical failure zones, with most estimates falling within a conservative threefold error margin. The proposed framework balances predictive reliability with computational efficiency, providing a practical tool for defect-sensitive fatigue assessment. By combining experimental evidence with validated modeling, the study advances the understanding of localized residual stress and stress concentration effects on fatigue degradation in high-strength aluminum alloys.