Very high cycle fatigue and fatigue crack growth of steels: a review

Monisha Manjunatha; Yevgen Gorash; Tugrul Comlekci; Lewis Milne; Donald Mackenzie

doi:10.3390/app16041737

Very high cycle fatigue and fatigue crack growth of steels: a review

Monisha Manjunatha^*, Yevgen Gorash^*, Tugrul Comlekci, Lewis Milne, Donald Mackenzie

^*Corresponding author for this work

Mechanical And Aerospace Engineering

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Abstract

This review presents a comprehensive examination of the total fatigue life behaviour of high-strength steels (HSS) with particular emphasis on fatigue crack initiation in the very high cycle fatigue (VHCF) regime and crack propagation based on fracture mechanics. The discussion draws on recent advances in experimental techniques, microstructural characterisation, and analytical approaches by reviewing studies conducted over the past few years. Key factors influencing fatigue performance, including loading frequency, specimen geometry, microstructure, and environmental conditions, are critically evaluated. The review concludes by highlighting existing knowledge gaps and outlining directions for future research aimed at improving the understanding and optimisation of fatigue performance in current and next-generation HSS.

Original language	English
Article number	1737
Number of pages	32
Journal	Applied Sciences
Volume	16
Issue number	4
DOIs	https://doi.org/10.3390/app16041737
Publication status	Published - 10 Feb 2026

Funding

The research in this paper was funded by the Weir Group PLC (project ID WARC2011-SAA1, 2011) via its establishment of the Weir Advanced Research Centre (WARC) at the University of Strathclyde.

Keywords

fatigue life
crack initiation
very high cycle fatigue
crack growth
steels
ultrasonic fatigue testing

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10.3390/app16041737Licence: CC BY 4.0

Manjunatha-etal-AS-2026-Very-high-cycle-fatigue-and-fatigue-crack-growth-of-steelsFinal published version, 9 MBLicence: CC BY 4.0

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abstract = "This review presents a comprehensive examination of the total fatigue life behaviour of high-strength steels (HSS) with particular emphasis on fatigue crack initiation in the very high cycle fatigue (VHCF) regime and crack propagation based on fracture mechanics. The discussion draws on recent advances in experimental techniques, microstructural characterisation, and analytical approaches by reviewing studies conducted over the past few years. Key factors influencing fatigue performance, including loading frequency, specimen geometry, microstructure, and environmental conditions, are critically evaluated. The review concludes by highlighting existing knowledge gaps and outlining directions for future research aimed at improving the understanding and optimisation of fatigue performance in current and next-generation HSS.",

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AU - Mackenzie, Donald

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N2 - This review presents a comprehensive examination of the total fatigue life behaviour of high-strength steels (HSS) with particular emphasis on fatigue crack initiation in the very high cycle fatigue (VHCF) regime and crack propagation based on fracture mechanics. The discussion draws on recent advances in experimental techniques, microstructural characterisation, and analytical approaches by reviewing studies conducted over the past few years. Key factors influencing fatigue performance, including loading frequency, specimen geometry, microstructure, and environmental conditions, are critically evaluated. The review concludes by highlighting existing knowledge gaps and outlining directions for future research aimed at improving the understanding and optimisation of fatigue performance in current and next-generation HSS.

AB - This review presents a comprehensive examination of the total fatigue life behaviour of high-strength steels (HSS) with particular emphasis on fatigue crack initiation in the very high cycle fatigue (VHCF) regime and crack propagation based on fracture mechanics. The discussion draws on recent advances in experimental techniques, microstructural characterisation, and analytical approaches by reviewing studies conducted over the past few years. Key factors influencing fatigue performance, including loading frequency, specimen geometry, microstructure, and environmental conditions, are critically evaluated. The review concludes by highlighting existing knowledge gaps and outlining directions for future research aimed at improving the understanding and optimisation of fatigue performance in current and next-generation HSS.

KW - fatigue life

KW - crack initiation

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KW - ultrasonic fatigue testing

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Very high cycle fatigue and fatigue crack growth of steels: a review

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