journal article·2025-12Open access

Fretting and fatigue assessment of scalmalloy and AL7075-T651 shrink-fitted shafts

D. Erena, M. Moreno-Rubio, Andrea Zanichelli, Jesús Vázquez, Carlos Navarro

Abstract

• Fatigue comparison of AL7075-T651 and Scalmalloy in shaft-hub assembly. • Fretting fatigue model for shaft-hub assembly. • Testing and microscopy of both materials in simple fatigue and fretting fatigue in actual assembly. This work aims to study the effect of additive manufacturing under fretting fatigue conditions, an area in which there is still very little information. For this purpose, two test campaigns were carried out on a shaft-hub assembly subjected to bending using two different materials: the AL7075-T651 aluminium alloy and an aluminium alloy specifically designed for additive manufacturing, Scalmalloy®. To determine the contact stress and strain fields at the crack initiation site, a 3D FEM model was designed using the sub-model technique. After the tests, the crack paths were measured using a confocal microscope and compared with the numerical assessments. Finally, a traditional stress-based fatigue model was applied to predict the failure of the components, yielding estimations within a scatter band of 2.
Source: openalex_inverted_index · Quality: baseline

Research context

OpenAlex topics: Mechanical stress and fatigue analysis · Mechanical Failure Analysis and Simulation · Mechanical Engineering and Vibrations Research

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (45)

Show source-provided references
1. Spierings a, Karl Dawson b, Mark Voegtlin a, Frank Palm c, Peter J. Uggowitzer, Microstructure and mechanical properties of as-processed scandium-modified aluminium using selective laser melting. CIRP Annals. Volume 65, Issue 1, 2016, Pages 213-216.10.1016/j.cirp.2016.04.057 ↗
2. Scalmalloy® a Unique High Strength AlMgSc Type Material Concept Processed by innovative Technologies for Aerospace Applications PM2010 World Congress –
3. A review of selective laser melting of aluminum alloys: processing, microstructure, property and developing trends10.1016/j.jmst.2018.09.004 ↗
4. Selective laser melting of aluminum components10.1016/j.jmatprotec.2010.09.019 ↗
5. Aboulkhair NT, Everitt NM, Ashcroft I, Tuck C. Reducing porosity in AlSi10Mg parts processed by selective laser melting. Addit Manuf 2014;1:77–86. https://doi. org/10.1016/j.addma.2014.08.001.10.1016/j.addma.2014.08.001 ↗
6. Process dependent porosity and the influence of shot peening on porosity morphology regarding selective laser melted AlSi10Mg parts
7. The effect of stress relief on the mechanical and fatigue properties of additively manufactured AlSi10Mg parts10.3390/met9111216 ↗
8. Stopyra W, Gruber K, Smolina I, Kurzynowski T, Kuznicka B. Laser powder bed fusion of AA7075 alloy: influence of process parameters on porosity and hot cracking. Addit Manuf October 2020;35:101270. https://doi.org/10.1016/j.addma.2020.101270.10.1016/j.addma.2020.101270 ↗
9. Laser powder bed fusion of nano-CaB6 decorated 2024 aluminum alloy10.1016/j.jallcom.2021.158714 ↗
10. The manufacturing of hard tools from metallic powders by selective laser melting10.1016/S0924-0136(01)00522-2 ↗
11. In situ alloying and reinforcing of Al6061 during selective laser melting10.1016/j.procir.2018.08.009 ↗
12. D. W. J. W. R. Russell, B. Poorganji, E. Ott, T. Nakagawa, H. Sandoval, N. Shamsaei y M. Seifi, «Qualification and certification of metal additive manufactured hardware for aerospace applications,» de Additive Manufacturing for the Aerospace Industry, vol. 84, Eds. F. Froes y R. Boyer, 2019.10.1016/B978-0-12-814062-8.00003-0 ↗
13. Comparison of the porosity and mechanical performance of 316L stainless steel manufactured on different laser powder bed fusion metal additive manufacturing machines10.1016/j.jmrt.2021.06.027 ↗
14. Investigations on the fretting fatigue failure mechanism of bolted joints in high strength steel subjected to different levels of pre-tension10.1016/j.triboint.2016.11.014 ↗
15. GOLDEN, Patrick J. Development of a dovetail fretting fatigue fixture for turbine engine materials. International Journal of Fatigue, 2009, vol. 31, no 4, p. 620-628.10.1016/j.ijfatigue.2008.03.017 ↗
16. A review of analytical aspects of fretting fatigue, with extension to damage parameters, and application to dovetail joints10.1016/S0020-7683(00)00136-0 ↗
17. Mechanism of fretting fatigue in steel cables10.1016/0142-1123(94)90341-7 ↗
18. Fretting fatigue in electrical transmission lines10.1016/0043-1648(94)90271-2 ↗
19. Fretting fatigue in overhead conductors: rig design and failure analysis of a Grosbeak aluminium cable steel reinforced conductor10.1016/j.engfailanal.2008.01.003 ↗
20. Winkler J, Georgakis CT, Fischer G. Fretting fatigue behavior of high-strength steel monostrands under bending load. Int J Fatig 2015;70:13–23. https://doi.org/ 10.1016/j.ijfatigue.2014.08.009.10.1016/j.ijfatigue.2014.08.009 ↗
21. Fretting fatigue of a shrink-fit pin subjected to rotating bending: experiments and simulations10.1016/j.ijfatigue.2009.04.019 ↗
22. Finite element simulation of the influence of fretting wear on fretting crack initiation in press-fitted shaft under rotating bending
23. Fretting fatigue tests on shrink-fit specimens and investigations into the strength enhancement induced by deep rolling10.1016/j.ijfatigue.2015.08.007 ↗
24. Fretting fatigue analysis of additively manufactured blade root made of intermetallic Ti-48Al-2Cr-2Nb alloy at high temperature10.3390/ma11071052 ↗
25. Fretting and Fretting Corrosion Behavior of Additively Manufactured Ti-6Al-4V and Ti-Nb-Zr Alloys in Air and Physiological Solutions10.3390/jfb15020038 ↗
26. Fatigue behavior of notched and unnotched AM Scalmalloy specimens subjected to different surface treatments10.1016/j.ijfatigue.2024.108146 ↗
27. Numerical study on the influence of artificial internal stress relief groove on fretting fatigue in a shrink-fitted assembly10.1016/j.triboint.2020.106443 ↗
28. D. Schimbäck, P. Mair, L. Kaserer, L. Perfler, F. Palm, G. Leichtfried y S. Pogatscher, An improved process scan strategy to obtain high-performance fatigue properties for Scalmalloy®,Materials & Design, vol. 224, 2022.10.1016/j.matdes.2022.111410 ↗
29. Erena, D., Vázquez, J., Navarro, C. y Domínguez, J. (2023). Caracterización de la aleación Scalmalloy y comparación entre fabricantes. En 39 Congreso del Grupo Español de Fractura GEF2023. Revista Española de Mecánica de la Fractura, vol. 6 (267-272), Sociedad Española de Integridad Estructural - Grupo Español de Fractura.
30. Microstructural mechanisms of cyclic deformation, fatigue crack initiation and early crack growth
31. Study of the shot peening surface roughness in fretting10.1016/j.triboint.2024.109444 ↗
32. Fretting wear-induced evolution of surface damage in press-fitted shaft10.1016/j.wear.2017.05.014 ↗
33. A fretting fatigue model based on self-steered cracks10.1016/j.tafmec.2021.103144 ↗
34. Influence of grain size and grain-size distribution on workability of granules with 3D printing10.1007/s00170-013-5210-8 ↗
35. Fatigue of 7075-T651 aluminum alloy10.1016/j.ijfatigue.2007.07.005 ↗
36. Effect of the heat treatment on the mechanical properties and microstructure of Scalmalloy® manufactured by Selective Laser Melting (SLM) under certified conditions10.1016/j.matchar.2022.112549 ↗
37. Fretting-fatigue analysis of shot-peened al 7075-t651 test specimens10.3390/met9050586 ↗
38. Effect of rolling on fretting fatigue assessment of cylindrical contact in partial slip regime10.1016/j.triboint.2023.108772 ↗
39. Early cracking orientation under high stress gradients: the fretting10.1016/j.ijfatigue.2016.12.013 ↗
40. Life prediction in multiaxial high cycle fretting fatigue10.1016/j.ijfatigue.2020.105504 ↗
41. Critical plane orientation influence on multiaxial high-cycle fatigue assessment10.1134/S1029959915040074 ↗
42. Welded joints under multiaxial non-proportional loading10.1016/j.tafmec.2017.08.004 ↗
43. Fatigue behaviour assessment of ductile cast iron smooth specimens10.1016/j.ijfatigue.2021.106459 ↗
44. Fatigue lifetime of both plain and notched specimens made of additively manufactured AISI 316L10.1016/j.jmrt.2022.10.068 ↗
45. Influence of normal load frequency on fretting fatigue behaviour by a critical plane-based approach10.1016/j.ijfatigue.2022.106724 ↗