Introduction of a reverse simulation approach to identify the fatigue stress intensity factor crack arrest threshold from fretting cracking experiments

•We compare the resistance in partial slip fretting loadings of two Al-alloys.•We use a reverse FEM analysis to calculate the ΔKth.•We model the crack and the friction coefficient in it.•A methodology is established to estimate the ΔK0 for long cracks.•We quantify ΔKth(fr) versus the crack length through a K–T, El-Haddad formalism.

The aim of this study was to estimate the ΔKth crack arrest stress intensity factor related to the crack arrest condition of a material subjected to partial slip fretting loadings, by coupled experimental and numerical simulation. The study focuses on a plane (Al-alloy)/cylinder (TA6V) interface. Fretting tests were performed for each configuration to obtain the crack length as a function of the number of fretting cycles, in order to establish the crack length related to crack arrest condition. Using a reverse FEM analysis of crack arrest fretting experiments, the thresholds ΔKth(fr) are extracted. Two 2196-T8 and 2196-UA aluminium alloys were compared, while the short crack arrest versus the crack length evolutions were formalized using a Kitagawa Takahashi formalism.