Fatigue Criticality Assessment of Volumetric Defects in Notched Specimens: A Non‐Destructive Approach

ABSTRACT This study utilizes linear elastic fracture mechanics to assess the fatigue criticality of volumetric defects in notched specimens with varying geometries. Contrasting to the existing literature, this study assesses the fatigue criticality of defects, prior to fracture, via a non‐destructive inspection technique, that is, X‐ray computed tomography (XCT). Treating volumetric defects as cracks, based on Murakami's definition, the approach calculates their Mode‐I stress intensity factor (SIF) with their local stresses obtained via linear elastic finite element analysis and utilizes the SIF to represent their criticality. For validation, cylindrical and flat specimens with notch root radii of 5 and 50 mm of AlSi10Mg and 17‐4 precipitation hardened stainless steel were fabricated, XCT scanned, and tested under fatigue loading. All crack initiating defects, observed from fractography, fell within the 99.3 percentile of the defects with the highest stress intensity factor in the respective specimens.