7 facts about material fatigue and why early inspections are crucial
What is material fatigue and why is it so dangerous?
Material fatigue, also known as Vibration fracture or Fatigue fracture known, occurs when a material is subjected to repeated cyclical loads is exposed to. These loads may be below the actual strength limit of the material, but over time they lead to Microcrackswhich gradually spread and eventually lead to a sudden break. Particularly in industries such as the Automotive and aviation industryWhere materials are exposed to extreme conditions, material fatigue is a serious threat. Breakages can jeopardise the functionality of machines and even lead to safety-critical incidents.
A striking example of material fatigue are Fatigue cracks on metallic materials that form over long periods of time under alternating loads. These cracks are often caused by so-called Rest lines and Swing stripmarked on the fracture surfaces to indicate the progress of the fracture.
Fractographythe examination of the fracture surfaces, plays a central role in the Analysing material fatigue. Through a combination of macroscopic and microscopic examinations the causes of cracks can be identified and measures taken to prevent future cracks.
The challenge with material fatigue is that it often goes unnoticed until complete failure occurs. Therefore Regular inspections essential to recognise early signs of cracks. Non-destructive testing methods, such as Visual inspections, Ultrasound measurements and modern Drone inspectionsoffer effective solutions for identifying microcracks in vulnerable components and taking preventive measures in good time.
1. material fatigue as a result of cyclical loads
Material fatigue is a complex phenomenon caused by repeated cyclic loads that are below the material's yield strength. These loads lead to progressive damage to the microstructure of the material, which manifests itself in the formation of microcracks. With each load change, these microcracks gradually increase in size until they reach a critical size that leads to failure of the component. In contrast to plastic deformation, material fatigue does not result in immediate deformation, which makes it difficult to recognise the damage in the initial stages. However, accumulated damage can lead to sudden and catastrophic failure if it is not detected early.
2. over 70 % of structural failures in the industry are fatigue failures
Studies show that more than 70 % of structural failures in machines and technical components are due to fatigue fractures. This high proportion emphasises the important role that material fatigue plays in mechanical design. Components that are subject to repeated load cycles, such as rotating machine components, crankshafts, gear wheels or aeroplane wings, are particularly affected. These fatigue failures often occur under conditions that are not considered critical in normal operation, which is why early detection of microcracks and inspection of these components are crucial to prevent sudden failure.
3. specific features such as vibration stripes and detent lines indicate material fatigue
The analysis of fracture surfaces caused by material fatigue is a central component of the Fractographya discipline that deals with the microscopic and macroscopic examination of fracture patterns. Typical characteristics of a fatigue fracture are Rest lineswhich appear as shell-like patterns on the fracture surface and reflect the progress of crack formation over time. These lines are caused by the intermittent progression of the crack under cyclic loads. In addition Swing strip which run as fine furrows perpendicular to the direction of crack propagation and can provide information about the number of load cycles. These microscopic and macroscopic features provide valuable information about the origin and progression of material fatigue.
4. visible damage due to material fatigue often only occurs at an advanced stage
One of the biggest problems with material fatigue is the invisibility of the early stages of damage. Microcracks initially occur at a microscopic level and remain invisible during the initial stages of crack growth. Only when the crack has reached a critical size do visible signs such as surface cracks or deformations become recognisable. At this point, however, the component is often already severely weakened and close to failure. For this reason, it is crucial to use inspection methods that can detect even the smallest cracks before they become a serious hazard.
5 In the automotive and aerospace industries, regular inspections are essential for detecting fatigue cracks
Material fatigue poses a significant challenge, particularly in safety-critical industries such as the automotive and aerospace industries. Components used in vehicles, aeroplanes or spacecraft are repeatedly exposed to alternating loads that cause material fatigue. The safety of passengers and crews depends heavily on the structural integrity of these components. Regular inspections and non-destructive testing (NDT) to detect potential cracks at an early stage and minimise the risk of unforeseen failure. Inspections also enable engineers to monitor the service life of components and plan preventive maintenance measures before major damage occurs.
6 Non-destructive testing is the key to early detection of material fatigue
Non-destructive testing (NDT) offers a decisive advantage in the detection of material fatigue, as it monitors the condition of components without damaging them. The most commonly used methods include Visual inspectionswhere surface cracks are visually inspected, and Ultrasound measurementswhich make it possible to recognise the formation of cracks inside a material. Furthermore Drone inspections are playing an increasingly important role, especially in difficult to access or hazardous environments. These modern technologies enable the early detection of cracks and help to significantly reduce the risk of material failure. Regular non-destructive inspections can prevent impending failures, thereby improving both the safety and service life of components.
7. preventive design measures can significantly extend the service life of components
In order to reduce the risk of material fatigue, preventive measures are increasingly being used in construction. These measures include, among other things Optimisation of the geometry of components to avoid stress peaks. Abrupt changes in cross-section and sharp edges increase the likelihood of cracking and should therefore be avoided. In addition Surface treatments how the Shot peening are used to introduce residual compressive stresses into the surface of the material. These stresses counteract the propagation of cracks and increase the service life of components that are exposed to cyclic loads. By combining these measures with regular inspections, the probability of fatigue fracture can be significantly reduced.
Conclusion
Material fatigue is a constant challenge in industrial applications. Maintenance as it can lead to the unexpected failure of components due to cyclical loads. Early detection of fatigue cracks is crucial to prevent failures and ensure safety. Non-destructive testing methods and regular inspections are essential to continuously monitor the condition of components. In particular, the use of Flyability ELIOS 3 The drone offers a major advantage here. With the ELIOS 3, even hard-to-reach areas can be easily inspected. Even if there is only a Visual inspection is possible, the Frequent inspection The drone enables reliable monitoring without the need to erect scaffolding or use climbers. This method not only saves costs, but also increases safety and efficiency during inspections, which extends the service life of systems in the long term.
Request a drone inspection
- We look forward to your enquiry and will respond promptly!
English 
German 
Dutch 
Danish 
Swedish 
Norwegian 
