Damage prediction for un-coated and coated aluminum alloys under thermal and mechanical fatigue loadings based on a modified plastic strain energy approach

•A new energy-based lifetime prediction model is presented for coated A356.0 alloy.•Correction factors for stress, temperature and strain effects are considered.•The model can be used for coated/un-coated condition, under TMF/LCF loadings.•Comparing to Sehitoglu’s model, new model is simpler and has no limitations.

In this article, a novel energy-based lifetime prediction model has been presented for uncoated and coated aluminum alloys, subjected to thermal and mechanical fatigue loadings. For this objective, isothermal and thermo-mechanical fatigue tests were performed on the A356.0 alloy, with and without thermal barrier coating systems. This model, which was based on the plastic strain energy, had three correction factors including temperature, strain and mean stress effects. The predicted lifetime showed a proper agreement with experimental data. By the present model, higher accuracy was obtained in comparison to other existed approaches. Besides, the present model had lower number of material constants.