The effect of interference-fit on fretting fatigue crack initiation and ΔK of a single pinned plate in 7075 Al-alloy

The effect of interference-fit on fretting fatigue crack initiation and ΔK was studied numerically for available experimental results in a single pinned plate in Al-alloy 7075-T6. The role of interference ratio was investigated alongside friction coefficient through finite element. Cyclic stress distributions in the plate ligament and fretting stresses on the contact interface were evaluated using 3-D elastic–plastic finite element models. Additionally a 3-D elastic finite element model was utilized to discuss ΔK of cracks emanating from interference fitted holes. Results demonstrate that fretting was the main reason for crack nucleation, and furthermore, the location was precisely predicted and fatigue life enhancement was explained.