Engineering Failure Analysis 131 (2022) 105812

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Engineering Failure Analysis

journal homepage: www.elsevier.com/locate/engfailanal

Experimental study of fretting fatigue in dovetail assembly

considering temperature effect based on damage
mechanics method
Debin Sun *, Junzhou Huo *, Hao Chen, Zhengliang Dong, Rong Ren
School of Mechanical Engineering, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian, Liaoning 116024, China

A R T I C L E I N F O A B S T R A C T

Keywords: Fretting fatigue of dovetail structure of aero-engine compressor is a very complex phenomenon,
Dovetail structure which is affected by different factors such as temperature, load, friction coefficient, and arc
Temperature effect radius, etc. Aiming at the problem of the high-temperature fretting fatigue life prediction of
Crack initiation
dovetail structure, the high-temperature effect on fretting fatigue life is analyzed, and then the
Fretting fatigue life
fretting fatigue life prediction model is established considering the temperature effect by intro­
ducing temperature equivalent factor based on the circular flat contact theory and continuous
damage mechanics theory. Besides, the criterion of fretting fatigue cracks initiation failure is
proposed based on the displacement–strain joint monitoring method in the fretting fatigue tests.
The experiment results show that the proposed fretting fatigue life prediction model has a high
life prediction ability within ± 2.0 times error band. It is found that the traditional damage
mechanics accumulation model cannot reflect the change of fretting fatigue damage only by
changing the material performance parameters in a high-temperature environment, needing
temperature correction and the proposed fretting fatigue life prediction model considering tem­
perature effect in the exponential form of temperature ratio is feasible.

1. Introduction

Fretting fatigue widely exists in rail transit, aerospace, biomedical and other fields, whose fretting damage is commonly known as
“cancer” in the industry [1], which refers to the phenomenon of fatigue strength reduction or early fracture of components because of
small amplitude relative sliding between a part of the surface and other contact surfaces under cyclic load and the fretting fatigue is
affected by different factors, such as temperature, load and friction coefficient, etc. As a paramount component of an aero-engine, the
compressor works in a harsh environment of high temperature, high pressure, and high speed, the joint surface between tenon and
groove of the dovetail structure is prone to fretting damage due to the centrifugal force and vibration load, resulting in a loosening of
the connection and inducing cracks. The high temperature is an important factor affecting fretting fatigue behavior, which accelerates
the initiation and propagation of fretting fatigue crack, and the fretting fatigue damage generated greatly reduces the service life of the
compressor [2]. Simultaneously, the fretting fatigue failure probability increases due to numerous dovetail structures under a high-
temperature environment. Therefore, to explore the temperature effect of dovetail structure and accurately predict the high-
temperature fretting fatigue life are still full of challenges.

* Corresponding authors.
E-mail addresses: sundebin_dlut@163.com (D. Sun), huojunzhou@dlut.edu.cn (J. Huo).

https://doi.org/10.1016/j.engfailanal.2021.105812
Received 21 June 2021; Received in revised form 13 September 2021; Accepted 14 October 2021
Available online 18 October 2021
1350-6307/© 2021 Elsevier Ltd. All rights reserved.
D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Given the fretting fatigue damage mechanism and the prediction of fretting fatigue crack initiation life of dovetail structure, many
scholars have studied and explored from the theoretical analysis, simulation calculation and experimental investigation. Deepak
Kumar et al. [3] studied the effect of heterogeneity on fretting fatigue stress based on DNS by using the single-hole cell model and a
four-hole cell model. Virendra Kumar Verma et al. [4] investigated the fretting fatigue behavior of Ti-6Al-4V under different contact
pressures and stress ratios. Nadeem Ali Bhatti et al. [5] explored the effect of both in-phase and out-of-phase loading on contact stresses
and damage initiation locations of fretting fatigue by FEA based on three-phase difference angles. Further, Nadeem Ali Bhatti et al. [6]
calculated the fretting fatigue life of the cylindrical pad with a flat specimen under different phase loading conditions, compared the
fretting fatigue life calculated by CDM and CP methods and accomplished experimental verification. Mario Lavella et al. [7] explored
the fretting fatigue of the blade root of the intermetallic compound Ti-48Al-2Cr-2Nb and obtained the optimal shape to minimize the
contact stress. Chen Hu et al. [8] designed the scale test of the dovetail structure to study the fretting fatigue and the experiments
verified the accuracy of total life prediction considering the crack closure effect. Sun Shouyi et al. [9] considered the influence of crystal
orientation on the fretting fatigue behavior of NBSX superalloy and the proposed fretting fatigue life prediction method considering
crack, wear and mutual influence was validated with experimental data. Nadeem Ali Bhatti et al. [10] analyzed the effect of stress
gradient and used the stress average method to explore and calculate the fretting fatigue crack initiation angle and life of the cylin­
drical pad. Qingming Deng et al. [11] studied the effect of the size, location of a single critical micro-void on the fretting fatigue
initiation life of heterogeneous materials by numerical simulations and modified critical plane criterion considering stress gradients. J.
A. Arazújo et al. [12] explored the influence mechanism of size and gradient effect on fretting wear life, established multiaxial fretting
fatigue crack initiation life, and used the new data established by Ti-6Al-4V cylindrical surface contact to perform model evaluation
and verification. A. L. Pinto et al. [13] used the fretting fatigue data of Al 2024-T3 alloy to verify the proposed fretting fatigue life
evaluation model considering the fretting wear effect. Teng Zhenjie et al. [14] achieved an ultra-high cycle fretting fatigue test with
mean stress on GCr15 bearing structure using the ultrasonic system and studied the fatigue strength of the material and the wear and
fracture mechanism of the damaged area. Wang Jingchen et al. [15] combined with numerical analysis and experimental design,
explored the bending fretting fatigue performance of GH4169 and constructed the SWT model considering the influence of subsurface
stress. However, the fretting fatigue life prediction methods for dovetail structure of aero-engine compressor mainly include critical
plane method [16], damage mechanics method [17], fretting specific parameter method [18], machine learning method [19], etc.
Among them, the critical plane method mainly focuses on the strain stress-energy system, and its core is the selection of damage
parameters, such as strain-based BM [20], KBM [21], and FS parameter methods [22], etc; Stress based FP [23], SSR [24], and MSSR
parameter methods [25], etc; Energy-based L [26] and SWT parameter methods [13], etc. The continuum damage mechanics models
mainly include the damage model of Lemaitre [27], Chaboche [28], and B-E [29]. The fretting-specific parameter method mainly
includes the Ruiz [30] and Ding [31] parameter methods.
Unfortunately, although an army of scholars have proposed the fretting fatigue life prediction model of dovetail structure, most of
them focused on the fatigue life of dovetail structure under single low, high cycle, or high-temperature conditions without considering
the influence of the temperature effect. Also, the mechanism of temperature effect on fretting fatigue life is still unclear owing to the
complexity of the high-temperature fretting fatigue problem. Additionally, the fretting fatigue life prediction methods have some
limitations: in the critical plane approach, the prediction accuracy of crack nucleation location, initial crack direction and critical plane
parameters are the focus of research; in continuous damage mechanics, the experimental measurement of damage threshold and the
determination of material parameters are full of challenges; the fretting specific parameter method is based on the experimental
observation and has no physical significance; machine learning method is a new method of fretting fatigue life prediction, needing
massive data as support. Briefly, the high temperature is of great importance to the fretting fatigue life, which urgently needs to explore
the high-temperature effect to accurately calculate the fretting fatigue life.
In this paper, the high-temperature effect is explored on the fretting fatigue life, and then the high-temperature fretting fatigue life
prediction model of dovetail structure is established considering the temperature effect by introducing temperature equivalent factor
according to the circular flat contact theory proposed by M Ciavarella and D A Hills, in which the temperature effect is considered in
the exponential form of temperature ratio. Furthermore, the criterion of fretting fatigue crack initiation failure is presented in the
fretting fatigue test conducted to use for verifying the effectiveness and practicability of the proposed model. Finally, the predicted life
comparison between the model with and without considering the temperature effect is performed.

2. Materials and methods

2.1. Theoretical analysis

2.1.1. Fretting fatigue damage evolution model

Fatigue damage is because of the gradual degradation of materials caused by the formation and growth of micro-cracks and holes,
whose initiation and early growth of damage are discontinuous and are affected by the heterogeneity of polycrystalline materials [32].
In damage mechanics, the thermodynamic state parameter D is introduced to show the surface density of microcracks and cavities in
any plane of the representative volume unit of the material to further express the degradation of material properties. Kachanov [33]
believed that the fatigue damage of the material can be characterized by the reduction of the effective bearing area of the material, and
the damage parameter D was defined as:

̃
A− A
D= (1)
A

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

where A is the undamaged area; A ̃ is the effective area bearing the load. When there is no damage inside the material, D = 0, when the
material fails, D = 1.
Based on the thermodynamic framework proposed by Lemaitre and Chaboche, Xiao et al. [34] proposed a continuous damage
accumulation model considering the effect of mean stress and deduced the evolution of damage variables, whose model can well
predict the fatigue life under elastic strain, as shown in Eq. (2).
[ ]m
dD Δσ
= (2)
dN σR (1 − D)

where Δσ is the stress range, N is the fatigue cycle life, σ R and m are the material fatigue damage characteristic parameters related to
temperature. The parameter σR is called resistance stress, which reflects the ability of the material to resist the accumulation of
damage.
Farris [35] assumed that the tensile stress peak at the trailing edge of the fretting contact area caused the crack initiation in fretting
fatigue and approximately expressed the maximum fretting fatigue stress σfretting as Eq. (3). In the analysis, the critical stress
component that causes damage, i.g., the fretting fatigue stress σfretting was introduced into Eq. (2) by Aditya A. Walvekar [36], and then
the damage evolution equation of fretting fatigue was acquired, as defined in Eq. (4).
√̅̅̅̅̅̅̅̅
μF T
σfretting = σ0 + 2ph (3)
FN
[ ]
dD σ fretting m
= (4)
dN σR (1 − D)

where Ph is the maximum contact pressure; σ 0 is the axial peak stress; FN is the normal load; FT is the tangential load.
Assuming that the fretting fatigue stress σfretting is constant in the damage rate evolution equation, N = 0, D = 0, and N = Nf, D = 1
when the material respectively is in undamaged and the failed state. Thence, the relationship between fretting fatigue life and fretting
fatigue stress σ fretting is attained by integrating from the undamaged state to the fully damaged state, such as Eq. (5).
( )
1 σR m
Nf = (5)
m + 1 σfretting

2.1.2. Fretting fatigue stress

It can be seen from Eq. (3) that the contact stress directly affects the prediction accuracy of the fretting fatigue life of the dovetail
structure and the high-stress gradient at the trailing edge of the dovetail contact zone brings new challenges to the accurate calculation
of the contact stress. Although the analysis based on the Hertz solution can be applied to calculate the contact stress of certain specific
contact geometries, such as the extrusion between two cylinders, the ball and the plane, the cylinder and the plane, it is necessary to
establish the contact model under the actual service conditions because of the complexity of the dovetail structure geometry and load
conditions.
Aiming at the narrow application range of the Hertz equation, based on the Hertz contact theory, D A Hills [37] and M Ciavarella
[38] proposed analytical solutions for the surface pressure and internal stress field of a circular flat punch, whose detailed geometric
model of the punch is displayed in Fig. 1.
The width of the punch is 2a with two arcs of radius R. And because of the symmetrical stress distribution, the moment M is zero.
The normal pressure distribution of the flat punch with rounded edges proposed by M Ciavarella is disclosed in Eq. (6).
{ [⃒ ⃒ ]}
bp(Φ) 1 ⃒sin(Φ + Φ0 ) ⃒sinΦ ⃒⃒ Φ + Φ0 Φ − Φ0 ⃒⃒sinΦ0
= − π
× (π − 2Φ0 )cosΦ + ln ⃒⃒ ⃒ × ⃒tan tan ⃒ (6)
P π − 2Φ0 − sin2Φ0 sin(Φ − Φ0 ) ⃒ 2 2

where b is half the length of the contact area after loading, P is the normal load per unit length, the relationship between the auxiliary

Fig. 1. Geometric model of punch.

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

angle Φ and x can be established as follows:

x
sin(Φ) = (7)
b
The auxiliary angle ϕ0 reflects the size of the contact area, which can be solved by the implicit Eq. (8), and the relevant parameters
in the equation can be calculated by Eqs. (9) and (10).
2PR π − 2Φ0 cotΦ0
= − (8)
a2 E* 4sin2 Φ0 2

a
b= (9)
sinΦ0

1 (1 − ν1 ) (1 − ν2 )
= + (10)
E* E1 E2

where a is the half-length of the contact area when there is no normal load, E1 and E2 are Young’s modulus of the punch and the plane
respectively, ν1 and ν2 are respectively the Poisson’s ratios of the punch and the plane.
Because the dovetail is a symmetrical structure, only one contact area is considered in the contact analysis in this paper, as revealed
in Fig. 2(a). When the dovetail structure is not subjected to centrifugal load, the contact area length is 2a, and when the dovetail
structure is subjected to centrifugal load, the centrifugal force can be decomposed into a tangential load Q parallel to the contact
surface and a normal load P perpendicular to the contact surface, as conveyed in Fig. 2(b), whose length of the dovetail contact area is
increased to 2b under the action of the normal load P, as shown in Fig. 2(c). Therefore, the dovetail structure can be simplified to the
form of a flat punch with a circular arc and plane extrusion, so the contact stress can be solved by the Ciavarella contact theory.

2.1.3. Fretting fatigue life prediction model considering the temperature effect
The influence mechanism of high temperature on the fretting fatigue life of the dovetail structure of the aero-engine compressor is
extremely complicated, which will affect the elastic-plasticity, wear resistance, crack initiation, propagation resistance, creep and
oxidation degree of the material. The traditional high-temperature fretting fatigue life prediction model of the dovetail structure did
not consider the influence of temperature and it is arduous to isolate a single parameter or material property to study the influence on
fretting fatigue, and simultaneously, it is formidable to directly quantify it. According to J. Szusta [39], based on many high-
temperature fatigue tests, the fatigue life Nf presented an approximately linear function relationship with the variation trend of
temperature T. Assuming that the fatigue life Nf (T) under a high-temperature environment can be expressed as Eq. (11):
Nf (T) = AT + B (11)
The force of the atomic bond of the material at the melting point temperature Tm cannot withstand any external load, meaning that
the material has no strength and the fatigue life is 0, i.g., the function converges to the point (Tm, 0); When the temperature T is room
temperature RT, the fatigue life is Nf (T) = Nf (RT) in the high-temperature environment, i.g., the function passes through the point (RT,
Nf (RT)), which can be respectively used to solve the coefficients A and B as:
B = − ATm (12)

Fig. 2. Simplified schematic diagram of dovetail structure.

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Nf (RT)
A= − (13)
Tm − RT
Furthermore, the relationship is gained between the high-temperature fatigue life Nf (T) and the room temperature fatigue life Nf
(RT) corrected by the equivalent factor in the form of temperature ratio, as indicated in Eq. (14).
( )
Tm − T
Nf (T) = Nf (RT) (14)
Tm − RT
At the same time, some scholars revised the room temperature fretting fatigue life prediction model based on the exponential form
of the temperature ratio, and then proposed a fretting fatigue life prediction model that considered the nonlinear effect of high
temperature. For example, Wang Nan [40] proposed an equivalent damage parameter Deq expressed in the exponential form of the
temperature ratio to further establish a fretting fatigue life prediction model considering the temperature effect based on the Farris
model; Based on NLCD fretting fatigue life prediction model, Wu Bowei [41] introduced the damage rate factor in the form of tem­
perature ratio index to gain the fretting fatigue life prediction model under a high-temperature environment. The above specific
theoretical model considering the temperature effect is disclosed in Table 1.
Based on the above research, the fatigue life Nf and temperature T are assumed to be better correlated with test data through an
exponential relationship in this paper. Thus, the temperature equivalent factor ν expressed in the exponential form of temperature ratio
was used, as exposed in Eq. (15), and the high-temperature fretting fatigue life prediction model was further established considering
the nonlinear effect of temperature, as exhibited in Eq. (16).
( )K
Tm − T
v= (15)
Tm − RT
( ) ( )
1 σ R m Tm − T K
Nf = (16)
m + 1 σfretting Tm − RT

Combining Eq. (3) of the contact stress of the aero-engine dovetail structure under actual service conditions, the high-temperature
fretting fatigue life prediction model was finally achieved considering the temperature nonlinear effect, as presented in Eq. (17).
⎛ ⎞m
( )K
1 ⎜ σR ⎟ Tm − T
Nf = ⎜
⎝ √̅̅̅̅̅̅ ⎟
⎠ (17)
m + 1 σ + 2p μFT Tm − RT
0 h FN

where Tm is the melting point of the material; T is the actual operating temperature; RT is the room temperature. In this paper, the
melting point of the material GH4169 is 1260 ◦ C and the room temperature is 20 ◦ C.

2.1.4. Failure judgment of dovetail structure crack initiation

The fretting fatigue life of the dovetail structure includes crack initiation life and crack propagation life. Owing to the high
sensitivity of high-temperature nickel-based alloys to notches, once the structure has cracks, it will quickly break. In general, the crack
initiation life accounts for 80%-90% of the total life [14], so the crack initiation life was regarded as the fretting fatigue life in this
paper. For the judgment of fretting fatigue crack initiation life, many scholars have adopted different methods. Sun Shouyi [42]
defined the crack initiation life as the number of cycles when the adjacent peak value of the displacement cycle curve exceeds 0.03 mm
and Liang Shi [43] defined it as 0.05 mm. Han Qinan [44] used the method of combining dynamic displacement and dynamic strain
and took the displacement variable of the test device to twice the initial displacement change as the fretting fatigue initiation life.
Aditya A. Walvekar [36] defined the crack initiation standard when the crack growth affects the measured normal force and
displacement.
The high-temperature fretting fatigue tests were accomplished in the closed space of the high-temperature furnace, hindering the
observation of cracks. In addition, the high-temperature strain gauge is expensive with the complication of the bonding process and the

Table 1
Different life prediction models considering the temperature effect.
Author Temperature correction factor Model

J. Szusta Tm − T (T − Tm ) ( Δεeq )
Nf (T) = − Nf RT,
Tm − RT( ) ( (T m − RT)
) 2
Wang Nan T n T n b
Deq = D 1 + Qeq = Q 1 + = AN−fretting
Tm ( Tm )
Wu Bowei T − T0 T − T0 − m [ ⎡( ) ⎤w
Rt = k 1+ ] [ ]− β Δεcr
Tm − T0 Tm − T0 σb − σeqv⋅max AII ⎢ eq
p⎥
Nf = ∙ ( ) ∙ ⎣ ⎦
aM−0 β (1 + β) AII − σ− 1 1 − 3b1 σH, mean 1 − 3b2 σH,mean 2

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

high requirements for the experiment. Therefore, for the comprehensive consideration of safety and economy, this paper adopted the
displacement–strain monitoring method to investigate the fretting fatigue crack initiation life of dovetail structure based on the
assumption that the stiffness of test specimens changes and cracks occur simultaneously. First, the room temperature fretting fatigue
test was implemented with different fatigue cyclic loads with the record of the displacement–strain measured data of the test system
and the strain gauge. Then, when the measured data had a sudden change or a data jump occurred as a benchmark, the corresponding
cycle life Nf was recorded, and the displacement measured were compared under the same Nf to determine the ΔD of Eq. (18) as the
basis for judging the failure.
ΔD = di+1 − di (i ≥ 1) (18)

where ΔD is the difference between the two adjacent displacements. di+1 and di are respectively the two adjacent displacements data in
the fretting fatigue tests.

2.2. Experimental study

2.2.1. Experimental materials

GH4169 is a Ni-Cr-Fe-based precipitation hardening deformation superalloy with excellent comprehensive properties in the
temperature range of − 253-700 ◦ C, which has good resistance of fatigue, radiation, oxidation and corrosion, good workability,
weldability and long-term structural stability, and has been widely exploited in aerospace, nuclear energy and petroleum industries
[45]. In this paper, high-temperature nickel base alloy GH4169 is employed as the dovetail material, whose chemical composition and
physical and mechanical properties are respectively displayed in Table 2 and Table 3.

2.2.2. Experiment equipment

To explore the fretting fatigue behavior of the dovetail structure, SDS100 electro-hydraulic servo fatigue testing machine designed
by Changchun Zhongji Testing Co., Ltd. is adopted, which can be used for tensile, compression, dynamic high cycle fatigue, low cycle
fatigue, static constant deformation rate, constant load rate, conventional mechanical properties test and high-temperature mechanical
properties test, as displayed in Fig. 3(a) and Fig. 3(b). The maximum dynamic test force is ± 100 kN with a frequency of 0.1–50 Hz and
a displacement stroke of ± 50 mm. The maximum temperature of a high-temperature furnace is about 1000 ◦ C with a temperature
error of 0.1 ◦ C. Meanwhile, a K-type thermocouple and temperature controller are employed to monitor the temperature in the furnace
to ensure the uniformity and stability of heating of the dovetail structure. Also, a VHX-600E electron microscope with an ultra depth of
field is used to observe microcracks with the advantages of over 25 times depth of field of traditional optical microscope and depth of
field superposition technology, as shown in Fig. 3(c), which can be exploited for material fracture analysis, appearance analysis,
processing device appearance observation and metallographic structure observation.

2.2.3. Design of specimen and fixture

To better reflect the mechanical characteristics of the dovetail structure, the structural parameters of dovetail specimens used in
this test refer to the actual size of a certain dovetail structure to design the scale specimen. The machining accuracy is 0.005 mm and
the surface roughness is Ra = 0.8 μm. The geometric dimensions and physical assembly of the designed dovetail structure specimen are
exposed in Fig. 4.
During the fretting fatigue test, it needs to ensure that the test specimen has good coaxiality and the dovetail structure still has
effective contact between the contact surfaces under high frequency. Therefore, it is indispensable to design the corresponding test
fixture, including adapter tube and test fixture, as appeared in Fig. 5. Among them, nickel-base superalloy K465 [46] is selected as the
test fixture material with the advantages of high strength, superior heat resistance and corrosion resistance, superior casting perfor­
mance and wide application range at 1050 ◦ C, and is commonly employed in the design of high-temperature test fixture.

2.2.4. Experimental process

According to the actual service environment of the dovetail structure of the aero-engine compressor, this paper adopts a force-
controlled loading method in the fretting fatigue test to apply a sine wave load with a load frequency of 10 Hz and a load ratio of
0.1. 13 groups of dovetail structure test specimens are designed, as revealed in Table 4.
To safely and scientifically perform the fretting fatigue test of the dovetail structure and achieve accurate test data, the specific
experimental procedure is designed as follows:
(1) Installation of the adapter tube and the fixture. Before the fretting fatigue test, the adapter tube and the test fixture are
respectively connected, and the chuck is adjusted to make the circumferential angle is zero between the upper and lower fixture.
(2) Installation of the dovetail structure test specimen. The vertical position of the chuck is adjusted to align the dovetail structure
test specimen with the pinholes on the high-temperature test fixture to install the pins.

Table 2
Main chemical components of GH4169.
Element C Cr Ni Co Mo Al Ti

Mass fraction/% 0.02–0.06 17–21 50–55 ≤1 2.8–3.3 0.2–0.8 0.65–1.15

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Table 3
Mechanical properties of GH4169 at different temperatures.
T(◦ C) E(GPa) v a(10− 6C− 1) ρ(g/cm3)
20 204 0.3 – 8.24
400 176 0.32 13.5 8.24

Fig. 3. Fretting fatigue test equipment: (a) SDS electro-hydraulic servo drive test system; (b) Temperature control system; (c) VHX-600 elec­
tron microscope.

Fig. 4. Dovetail structure size and physical assembly.

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Fig. 5. Adapter tube and fixture for fretting fatigue test: (a) Adapter tube; (b) Test fixture.

Table 4
Fretting fatigue test of dovetail structure.
T/◦ C Text group F/kN Number of tests

20 Test-1-1 12 1
Test-1-2 13.5 1
Test-1-3 15 1
400 Test-2-1 5 3
Test-2-2 5.5 3
Test-2-3 6 3
Test-2-4 7 3
Test-2-5 7.5 3
Test-2-6 8 3
Test-2-7 9 3
Test-2-8 9.5 3
Test-2-9 10 3
Test-2-10 11 3

(3) Load application. According to the fretting fatigue test schemes, the fretting fatigue tests under room temperature and high-
temperature environments are executed by adopting the force control method of sine load wave.
(4) Data collection. In the room temperature fretting fatigue test, the displacement–strain data measured by the system and the
strain gauge are meanwhile recorded. Among them, the dovetail structure test specimen with strain gauges is exhibited in Fig. 6(a). In

Fig. 6. Fretting fatigue test of dovetail structure at room temperature and high temperature: (a) Pasting of a strain gauge; (b) Clamping diagram.

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

the high-temperature fretting fatigue test, thermocouples were respectively fixed at the upper, middle and lower parts of the specimen,
as presented in Fig. 6(b).

3. Results and discussions

3.1. Solution of fretting fatigue stress at high temperature

To get fretting fatigue stress of dovetail structure under different working conditions, different discrete points were calculated
based on Eqs. (6)–(10), and then the dimensionless contact stress curves with different radii were acquired, as displayed in Fig. 7. Then
the peak pressure was extracted and the fretting fatigue stress was calculated by combining with Eq. (3).
Fig. 7 reveals the distribution curves of dimensionless contact pressure (− P(x)b/P) along the length of the contact zone with
different radii R = 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm and 1.6 mm, which can be seen from the figure that the pressure
distribution curve of the flat punch with circular arc presents a “saddle” shape, i.g., the pressure distribution curve is symmetrical
about the contact center. The peak pressure appears at the edge of the contact area (x/b → ± 1), the valley appears in the center of the
contact zone (x/b = 0), and a large pressure gradient appears at the edge of the contact zone. Moreover, with the increase of arc radius
R, the peak position of the pressure distribution curve is close to the center of the contact zone, the peak pressure and the pressure
gradient decrease. When the arc radius R increases to the half-width a of the contact area of normal load, it approaches 0, whose
contact model is equivalent to the contact between ball and plane, and the pressure distribution curve is equivalent to Hertz contact.
Through the above analysis, the peak pressure was extracted from the Ciavarella contact model under corresponding working
conditions. Meanwhile, the fretting fatigue stress σ fretting was analyzed and calculated under various working conditions by combining
with Eq. (3), as exposed in Table 5.

3.2. Crack initiation failure ΔD determination and verification

To reduce the data error caused by the instability of load and frequency in the initial fretting fatigue test, the test was saved from the
500th loading cycle, and the displacement was recorded every 0.008 s by the displacement sensor of the fatigue testing machine.
Firstly, cyclic loads with peak values of 12 kN, 13.5 kN, and 15 kN were respectively applied to the dovetail specimens, and the
measured displacement–strain data were recorded and saved under corresponding working conditions. More crucially, when
macroscopic plastic deformation or microcrack occurs in the dangerous weak part of the dovetail structure, plastic deformation will
occur due to the follow-up effect of strain gauge grid wire until fracture failure occurs. Subsequently, the measured strain data will
disclose the phenomenon of data mutation or data jump, as indicated in Fig. 8. Therefore, the cycle life of the dovetail structure was
recorded until the measured data of strain gauge changes abruptly. Concurrently, to eliminate the acquisition error caused by the
system during the test and ensure the accuracy of the judgment standard of crack initiation, the (Nf-30) cycle was compared with Nf,
and the adjacent displacement difference ΔD corresponding to the cycle life was gotten, which can be utilized as the basis for judging
the high-temperature fretting fatigue crack initiation failure of dovetail structure.
The 15 kN load case was taken as an example and it can be seen from the strain measurement data in Fig. 8 that the crack initiation
life of the dovetail structure is 12,105 cycles. Concurrent, by observing the displacement cycle curve, it is discovered that the difference
between the peak displacement of the 12,105 cycles and that of the 12,075 cycles is 0.04393 mm, as shown in Fig. 9(c). In the same

Fig. 7. Contact stress curve of dovetail with different radii.

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Table 5
Calculation results of fretting fatigue stress of dovetail under different working conditions.
Test group F/kN σ0 /MPa FT /kN FN /KN Ph/MPa σfretting/MPa

Test-2-1 5 116.4687 3.5355 3.5355 591.22 764.12

Test-2-2 5.5 128.1155 3.8891 3.8891 634.20 822.84
Test-2-3 6 139.7624 4.2426 4.2426 672.94 876.93
Test-2-4 7 163.0561 4.9497 4.9497 741.22 975.02
Test-2-5 7.5 174.7030 5.3033 5.3033 771.86 1020.23
Test-2-6 8 186.3499 5.6569 5.6569 800.66 1063.42
Test-2-7 9 209.6436 6.3640 6.3640 876.47 1169.77
Test-2-8 9.5 221.2905 6.7175 6.7175 911.70 1220.02
Test-2-9 10 232.9373 7.0711 7.0711 944.88 1268.00
Test-2-10 11 256.2311 7.7782 7.7782 1006.20 1358.47

Fig. 8. Measured data curve of strain gauge.

way, the peak displacement of the strain gage when it fails and the change in the peak displacement of the 30 cycles before failure are
obtained respectively under 12 kN and 13.5 kN loads, as revealed in Fig. 9(a-b). Additionally, the statistics of peak and valley values of
displacement corresponding to strain gauge failure under three kinds of loads are bared in Table 6. Thus, in this paper, the ΔD = 0.04
mm is taken as the critical displacement peak difference of fretting fatigue crack initiation failure of dovetail structure at high tem­
perature to further get the fretting fatigue life.
To verify the feasibility of the proposed crack initiation failure criterion, a fretting fatigue test was performed on the dovetail
structure specimen under the service condition of 400 ◦ C and 10 kN, and the peak displacement was recorded every 30 cycles until
ΔD ≥ 0.04. The super depth-of-field three-dimensional microscope VHX-600E was exploited, and the mesoscale observation based on
the 30 × depth-of-field technology of the specimen of the dovetail structure after the test presented that the rear edge of the contact
area on both sides of the dovetail groove has respectively appeared the microcracks with dimensions of 1455.10 μm and 1343.80 μm,
as displayed in Fig. 10, which can be concluded that the practicality of the combined displacement–strain monitoring method and the
feasibility of the fretting fatigue crack initiation failure judgment method.

3.3. Fretting fatigue experimental results

In this paper, the fretting fatigue tests of 13 groups of dovetail structure specimens were performed, including 3 groups at room
temperature and 10 groups at high temperature. Then according to the criterion of fretting fatigue crack initiation failure, the results of
fretting fatigue crack initiation life of dovetail structure at room temperature and high temperature are respectively exhibited in
Table 7.
From the failure test specimens, it can be seen that fretting fatigue fracture occurs at the rear edge of the contact area of the dovetail
under room temperature and high-temperature service conditions, as shown in Fig. 11.
To compare the influence of high temperature on the dovetail structure of an aero-engine compressor, the fatigue test results were

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Fig. 9. The displacement cycle number curve under different loads: (a) 12 KN; (b) 13.5 KN; (c) 15 KN.

analyzed under two temperature conditions, which can be seen from Fig. 12 that the decreasing rate of fretting fatigue life increases
steps by step with the increase of load at 400 ◦ C. Also, in the same fretting fatigue life range, the range of load peak at room tem­
perature is about 3 kN, while that at high temperature is about 1 kN, which indicates that the fretting fatigue life is greatly reduced at
high temperature, and its sensitivity to load is enhanced simultaneously.

3.4. Parameter determination and experimental verification of fretting fatigue life model

In this paper, based on the MATLAB software platform, the test results of Test-2-(1,3,4,6,7,9) were randomly selected to fit to attain

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Table 6
Statistics of peak displacement of strain gauge in failure under different service conditions.
Test group Load/KN Number of cycles/c Peak displacement/mm ΔD/mm

Test-1-1 12 28,885 0.53284 0.03824

28,915 0.57108
Test-1-2 13.5 19,806 0.57774 0.04058
19,836 0.61832
Test-1-3 15 12,075 0.55606 0.04393
12,105 0.59999

Fig. 10. Microcrack of dovetail contact area: (a) Front side; (b) Back side.

parameters for the fretting fatigue life model by the Levenberg-Marquardt algorithm and global optimization method, whose fitting
curve is exposed in Fig. 13.
The parameters in the fretting fatigue life prediction model of dovetail structure considering the temperature effect to be solved
were acquired by fitting σ fretting - Nf, whose k = − 34.8, m = 4.0, σ R = 1000, and the correlation fitting coefficient is 0.98, which conveys
the effectiveness of the fitting method.
Subsequently, by substituting the above parameters into Eq. (16), the relationship was got between the fretting fatigue life of the
dovetail structure and the variables of fretting stress and temperature, as shown in Eq. (19).
( )4.0 ( )− 34.8
1 1000 Tm − T
Nf = (19)
5.0 σfretting Tm − RT

To compare the prediction effect of fretting fatigue life with and without considering the temperature effect, the fretting fatigue life
of Test-2-(2,5,8,10) at high temperature is selected to predict and compare in this paper. According to Eq. (5), the fretting fatigue life
prediction model without considering the temperature effect is applied to predict the fretting fatigue life, whose parameter fitting
process is consistent with that of the fretting fatigue life prediction model with considering the temperature effect. By calculation, the
relevant fitting parameters of the fretting fatigue life prediction model without considering the temperature effect are m = 3.99, σR =
15473.02, and then the predicted fretting fatigue life is gained.
The prediction results of fretting fatigue life calculated by the model with and without considering the temperature effect were
compared with the experimental data respectively, whose error band of fretting fatigue life prediction is disclosed in Fig. 14.
It can be found from Fig. 14 that based on four groups of Test-2-(2,5,8,10), the prediction results of the high-temperature fretting
fatigue life prediction model with considering the temperature effect are all within ± 2.0 times error band, and the deviation is smaller
than that of fretting fatigue life prediction model without considering the temperature effect, which indicates that the prediction effect
of the fretting life prediction model considering the temperature effect is improved, proving that the accuracy and practicability of the
prediction model of fretting fatigue life at high temperature are improved by considering the influence of the temperature effect and it
is feasible to consider the temperature effect through the exponential form of temperature ratio.
To sum up, aiming at the problem of fretting fatigue life prediction of dovetail structure of aero-engine, this paper studies the
influence of the temperature effect on the fretting fatigue life of dovetail structure, and constructs the high-temperature fretting fatigue
life prediction model considering the effect of temperature by introducing the temperature equivalent factor v to modify the damage
accumulation model. Through the fretting fatigue tests verification, it is found that the established fretting fatigue life prediction model
considering temperature effect has high fretting fatigue life prediction ability, meaning that the traditional damage mechanics
accumulation model cannot reflect the change of fretting damage only by changing the material performance parameters, whose above
research not only lays a theoretical foundation for the high-temperature fretting fatigue life prediction of dovetail structure of aero-

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Table 7
Fretting fatigue test results of dovetail structure.
T/◦ C Test group Peak value/kN Test life/c Average life/c

20 Test-1-1 12 28,915 28,915

Test-1-2 13.5 19,836 19,836
Test-1-3 15 12,105 12,105
400 Test-2-1 5 179,562 197,661
197,525
215,896
Test-2-2 5.5 156,826 148,210
148,652
139,153
Test-2-3 6 115,894 121,214
128,791
118,956
Test-2-4 7 90,805 92,631
88,541
98,546
Test-2-5 7.5 55,517 55,950
58,742
53,591
Test-2-6 8 47,602 45,226
45,986
42,089
Test-2-7 9 30,202 35,925
35,045
42,526
Test-2-8 9.5 21,994 21,702
19,856
23,254
Test-2-9 10 12,001 12,005
13,210
10,804
Test-2-10 11 10,321 11,691
13,025
11,725

Fig. 11. Failure specimen of dovetail structure: (a) 400 ℃; (b) 20 ℃.

engine compressor but also provides an important theoretical reference for optimization improvement and life extension design of
dovetail structure.
Aditya A. Walvekar [36] proposed a fretting fatigue life model based on the continuous damage mechanics theory and the fretting
fatigue damage evolution equation was achieved by introducing fretting stress. However, the traditional fretting fatigue life prediction
model considers the effects of effective stress and plastic strain, whose fatigue prediction results are more conservative with outside ±
2.0 times error band, meaning that the fretting fatigue behavior is different from general fatigue behavior. Through the comparative
study of the fretting fatigue tests of dovetail structure at room temperature and high temperature, it is discovered that the fretting
fatigue life of the dovetail structure is seriously affected by the increase of temperature. The high temperature causes the degradation
of material properties, the change of fretting damage cannot be reflected only by the stress–strain coupled with damage parameters of
the traditional fretting fatigue damage accumulation model, and the model needs to be modified at a high temperature. Therefore, the
influence of the temperature effect expressed by the temperature equivalent factor on the dovetail structure is introduced into the

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Fig. 12. Fretting fatigue life under different working conditions.

Fig. 13. Fretting fatigue stress σfretting - Nf relation curve.

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Fig. 14. Error band of fretting fatigue life prediction with and without the temperature effect.

proposed model, whose rationality is verified by experiments.

On the one hand, the temperature effect of the dovetail structure degrades the material properties to further reduce the fretting
fatigue life. On the other hand, the fretting fatigue causes the initiation and propagation of cracks, which in turn increases the contact
area of the dovetail structure. When the contact surface is relatively slipped, the frictional work continues to increase, which leads to
the formation of plastic microcracks on the contact surface to develop into the failure of the structure. To solve the problem of the high-
temperature fretting fatigue life prediction of dovetail structure, the effect of temperature is considered in this paper, but only the
fretting fatigue condition at 400 ◦ C is considered. However, under other various temperature environments, the fretting fatigue
behavior still needs to be studied and the influence mechanism of the temperature effect is further clarified on fretting fatigue of
dovetail structure.

4. Conclusions

In this paper, the temperature effect has been analyzed, affecting the fretting fatigue life of dovetail structure at high temperature,
and the fretting fatigue life prediction model considering the temperature effect has been established, whose rationality and accuracy
were verified by experiments. Based on the results, the main conclusions are as follows:
(1) The fretting fatigue life prediction model considering the temperature effect by introducing temperature equivalent factor based
on the circular flat contact theory and continuous damage mechanics theory was presented in this paper, whose rationality is verified
by experiments. The model proposed has a better prediction ability compared with the experimental data, whose prediction results are
within ± 2.0 times the error band, which also shows the feasibility of considering the temperature effect in the exponential form of
temperature ratio.
(2) The fretting fatigue life of the dovetail structure is seriously affected by the increase of temperature and the traditional damage
mechanics accumulation model only considering the stress–strain coupled with damage parameters cannot reflect fretting fatigue
damage in a high-temperature environment, needing temperature correction, whose prediction results are outside ± 2.0 times error
band.
(3) The criterion proposed for the high-temperature fretting fatigue crack initiation failure is effective and practical. In the
experiment, the critical displacement peak difference of fretting fatigue crack initiation failure is ΔD = 0.04 mm. In the meantime,
microcracks of dimensions 1455.10 μm and 1343 μm have appeared in the contact area of the dovetail tenon.
(4) The proposed life prediction model considering the temperature effect in this paper can provide a theoretical basis and technical
support for the structural optimization design and damage tolerance design of the dovetail structure.

Declaration of Competing Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to
influence the work reported in this paper.

Acknowledgements

The authors gratefully acknowledge the financial support from NSFC-Liaoning United Key Fund (Grant No. U1708255), National

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D. Sun et al. Engineering Failure Analysis 131 (2022) 105812

Natural Science Foundation of China (Grant No. 51875076), National Key Research and Development Project (Grant No.
2018YFB1306701), Liaoning BaiQianWan Talents Program (Grant No. 2020921006).

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