Materials under fatigue experience progressive and localized structural damage when subjected to repeated or cyclic loading, even at stress levels below their yield strength. The process typically involves three stages: crack initiation at stress concentrators, gradual crack growth with each loading cycle, and final rapid failure once the crack reaches a critical size.
Fatigue failures are often unpredictable because cracks can grow internally without visible signs until sudden fracture occurs. Factors such as material microstructure, surface finish, environment, and loading conditions can significantly influence fatigue life and behavior. Engineers often use S-N curves (stress vs. number of cycles) to predict fatigue life and design safer components.
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