Fretting fatigue: Novel experiments and analysis
Abstract
This study presents a comprehensive experimental and analytical investigation into the fretting fatigue behavior of cold-sprayed ZE41A-T5 cast magnesium alloy, with particular emphasis on the influence of contact pressure, displacement amplitude, loading frequency, and crack initiation modeling. A custom-designed fretting fatigue test rig enabled decoupled application of displacement amplitude and axial loading to replicate service-relevant multiaxial stress states. To interpret the test results, a life prediction methodology was developed by integrating finite element modeling, stress concentration analysis, and the critical-plane-based Fatemi–Socie parameter. The modeling framework offers a practical and efficient tool for life prediction, reducing reliance on computationally intensive nonlinear analyses for each test scenario. The predictions demonstrate strong correlation with experimental results, with all data points falling within a ±1.5x scatter bands on life. Fractographic analysis further validated the modeling approach, confirming crack initiation at the upper trailing edge of the contact zone.
Publication Title
Tribology International
Recommended Citation
Ghadar, S., Phan, N., Timmons, A., Grendahl, S., & Fatemi, A. (2026). Fretting fatigue: Novel experiments and analysis. Tribology International, 221 https://doi.org/10.1016/j.triboint.2026.111988
