Fatigue crack propagation is a critical phenomenon that affects the structural integrity and lifetime of various engineering components. Over the years, finite element modeling (FEM) has emerged as a powerful tool for studying fatigue crack propagation and predicting crack growth behavior. This study offers a thorough overview of recent advancements in finite element modeling (FEM) of fatigue crack propagation. It highlights cutting-edge techniques, methodologies, and developments, focusing on their strengths and limitations. Key topics include crack initiation and propagation modeling, the fundamentals of finite element modeling, and advanced techniques specifically for fatigue crack propagation. This study discusses the latest developments in FEM, including the Extended Finite Element Method, Cohesive Zone Modeling, Virtual Crack Closure Technique, Adaptive Mesh Refinement, Dual Boundary Element Method, Phase Field Modeling, Multi-Scale Modeling, Probabilistic Approaches, and Moving Mesh Techniques. Challenges in FEM are also addressed, such as computational complexity, material characterization, meshing issues, and model validation. Additionally, the article underscores the successful application of FEM in various industries, including aerospace, automotive, civil engineering, and biomechanics.

The finite element method (FEM) is a widely used technique in research, including but not restricted to the growth of cracks in engineering applications. However, failure to use fine meshes poses problems in modeling the singular stress field around the crack tip in the singular element region. This work aims at using the original source code program by Visual FORTRAN language to predict the crack propagation and fatigue lifetime using the adaptive dens mesh finite element method. This developed program involves the adaptive mesh generator according to the advancing front method as well as both the pre-processing and post-processing for the crack growth simulation under linear elastic fracture mechanics theory. The stress state at a crack tip is characterized by the stress intensity factor associated with the rate of crack growth. The quarter-point singular elements are constructed around the crack tip to accurately represent the singularity of this region. Under linear elastic fracture mechanics (LEFM) with an assumption in various configurations, the Paris law model was employed to evaluate mixed-mode fatigue life for two specimens under constant amplitude loading. The framework includes a progressive analysis of the stress intensity factors (SIFs), the direction of crack growth, and the estimation of fatigue life. The results of the analysis are consistent with other experimental and numerical studies in the literature for the prediction of the fatigue crack growth trajectories as well as the calculation of stress intensity factors.

The main objective of this work was to present a numerical modelling of crack growth path in linear elastic materials under mixed-mode loadings, as well as to study the effect of presence of a hole on fatigue crack propagation and fatigue life in a modified compact tension specimen under constant amplitude loading condition. The ANSYS Mechanical APDL 19.2 is implemented for accurate prediction of the crack propagation paths and the associated fatigue life under constant amplitude loading conditions using a new feature in ANSYS which is the smart crack growth technique. The Paris law model has been employed for the evaluation of the mixed-mode fatigue life for the modified compact tension specimen (MCTS) with different configuration of MCTS under the linear elastic fracture mechanics (LEFM) assumption. The approach involves accurate evaluation of stress intensity factors (SIFs), path of crack growth and a fatigue life evaluation through an incremental crack extension analysis. Fatigue crack growth results indicate that the fatigue crack has always been attracted to the hole, so either it can only curve its path and propagate towards the hole, or it can only float from the hole and grow further once the hole has been lost. In terms of trajectories of crack propagation under mixed-mode load conditions, the results of this study are validated with several crack propagation experiments published in literature showing the similar observations. Accurate results of the predicted fatigue life were achieved compared to the two-dimensional data performed by other researchers.

Fatigue crack growth modeling is critical for assessing structural integrity in various engineering applications. Researchers and engineers rely on 3D software tools to predict crack propagation accurately. However, choosing the right software can be challenging due to the plethora of available options. This study aimed to systematically compare and evaluate the suitability of seven prominent 3D modeling software packages for fatigue crack growth analysis in specific applications. The selected software tools, namely ABAQUS, FRANC3D, ZENCRACK, LYNX, FEMFAT, COMSOL Multiphysics, and ANSYS, were subjected to a comprehensive analysis to assess their effectiveness in accurately predicting crack propagation. Additionally, this study aimed to highlight the distinctive features and limitations associated with each software package. By conducting this systematic comparison, researchers and engineers can gain valuable insights into the strengths and weaknesses of these software tools, enabling them to make informed decisions when choosing the most appropriate software for their fatigue crack growth analysis needs. Such evaluations contribute to advancing the field by enhancing the understanding and utilization of these 3D modeling software packages, ultimately improving the accuracy and reliability of structural integrity assessments in relevant applications.

Metal alloy matrix composites are generally lightweight structural materials with a high strength-to-weight ratio. They can be extensively used in various fields of modern engineering applications, such as aerospace and automotive components and biomedical engineering. This study focuses on the development and characterization of lightweight metal alloy matrix composites for industrial applications, with a particular emphasis on magnesium (Mg) alloys as a replacement for aluminum-based alloys. Mg alloys offer significant weight advantages, being 33% lighter than aluminum and 75% lighter than steel, making them highly desirable for use in various engineering fields. In the present study, Mg (AZ91) alloy reinforced with x-Si₃N₄ composites (x = 0, 1, 3, 5, 7, 9 wt.%) were fabricated using a liquid state process. The AZ91/x-Si₃N₄ composites were evaluated through physical, mechanical, wear, and microstructural characterization. The experimental results, supported by statistical analysis, demonstrated that the incorporation of Si₃N₄ particles amplified the mechanical properties, wear resistance, and porosity of the composites. However, the presence of the reinforced particles resulted in reduced forgeability and elongation, limiting certain deformation characteristics. The existence of the reinforced particles within the composites was confirmed through SEM analysis, providing visual evidence of their distribution and interaction within the Mg alloy matrix. Finally, it was concluded that the implication of the study could be sought for the light structural parts of aerospace, automotive, biomedical, and prosthetic applications.

This work concentrates on the fracture behaviour of the compact tension specimen under mixed‐mode loading, and numerical investigation using ANSYS Mechanical APDL 19.2 finite element program with different modes of mix angles is carried out. The prediction of mixed‐mode fatigue life under constant amplitude fatigue loading for the compact tension shear specimen (CTS) is employed using Paris’ law model for two different loading angles with agreement to the experimental results. The predicted values of ΔK_eq were compared with the experimental and analytical data for various models. Depending on the analysis, the findings of the present study show consistency with the results achieved with similar models of predicting the equivalent stress intensity factor. In addition, the direction of crack growth derived from the analysis was observed to follow the same trend of the literature experimental results.