In this study, the main purpose is to analyze the fatigue failure of thermoplastic polyurethane (TPU) plate under tension-tension load control tests (frequency = 5 Hz, stress ratio = 0.1) and consider the change in hydrogen bond content. The results show that the S-N curve of TPU material shows a downward trend before reaching the fatigue limit (10.25 MPa), and the energy is continuously consumed during the cyclic creep process and undergoes three stages of the hard segment and the soft segment changes. The infrared spectrum study shows that the increase in fatigue life will lead to more physical crosslinking, resulting in the reduction of hydrogen bond content, and the increase in microphase separation, leading to the occurrence of fatigue fracture. In addition, the scanning electron microscope and three-dimensional confocal analysis showed that the crack originated from the aggregation of micropores on the surface of the material and was accompanied by the slip of the molecular chain, the crack propagation direction was at an angle of about 45°.

The very high cycle fatigue (VHCF) failure of in-service components is mainly caused by the vibration of thin-wall elements at a high frequency. In this work, a novel model of ultrasonic fatigue test was developed to test thin-wall material in bending up to VHCF with an accelerated frequency. The theoretical principle and finite element analysis were introduced for designing a sample that resonated at the frequency of 20 kHz in flexural vibration. In the advantage of the second-order flexural vibration, the gauge section of the sample was in the pure bending condition which prevented the intricate stress condition for thin-wall material as in the root of cantilever or the contact point of three points bending. Moreover, combining the constraint and the loading contact in one small section significantly reduced heating that originated from the friction at an ultrasonic frequency. Both strain gauge and deflection angle methods were applied to verify the controlling of stress amplitude. The fractography observation on Ti6Al4V samples indicated that the characterized fracture obtained from the novel model was the same as that from the conventional bending test.

The very high cycle fatigue (VHCF) problems of thin-plate structures are usually caused by high-frequency vibrations. This paper proposes an accelerated fatigue test method based on ultrasonic loading technology in order to develop a feasible bending testing method and explore the bending fatigue characteristics of thin-plate structures in the VHCF regime. A new bending fatigue specimen with an intrinsic frequency of 20 kHz was designed based on cantilever bending through finite element simulation. It was verified by the axial load test with R = −1. The results showed that the method could effectively transfer the dangerous cross-section at the first-order cantilever bending restraint to the internal part of the specimen, thereby making the fracture location independent of the complex stresses. The linear relationship between the vibration amplitude and the maximum stress was also verified using strain measurements. Furthermore, the S-N curves and fracture morphology for different loading types were consistent with conventional studies to a certain extent, which indicated that the design of the bending test model was reasonable.

Nanoindentation measurements were conducted to investigate the high-cycle response of 316L stainless steel in bending fatigue. Hardness variation owing to the gradient flexure stress amplitude for different curvatures was plotted along with the thickness and length, respectively. Scanning electron microscopy (SEM) was subsequently conducted to explore the deformation characteristics in multiple layers, which had cyclic gradient stress, on the cross-section of specimens. The nanoindentation results indicated that the cyclic hardening response of 316L stainless steel is correlated with the level of stress amplitude in the high-cycle fatigue (HCF) regime. Furthermore, an analytical model was proposed to clarify the relationship between nanohardness and stress amplitude. Finally, the evolution of damage accumulation due to irreversible plastic deformation is continuous during stress reduction up to the neighboring zone at the neutral surface of the flexure beam in some individual grains.