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Mixed-mode loading conditions are present in different mechanical components. Understanding the influence of in-plane biaxial loading paths parameters allows for fatigue crack growth (FCG) prediction and component fatigue life assessment. Cruciform specimens are used to simulate these conditions, but large specimen dimensions are required in order to keep crack propagation unaffected by specimen geometry. This article describes the procedure used to optimize a new cruciform specimen geometry, with small dimensions. Having identified the specimen arms fillet as a major source of crack growth interference, this effect was kept to a minimum, while using arm slots with different widths and lengths. Individual slot dimensions were optimized using a Direct MultiSearch (DMS) algorithm, minimizing the stress intensity factor (SIF) difference between the optimal specimen and an infinite plate. FCG on the optimized specimen was simulated under in and out-of-phase loading conditions. Due to crack closure effects, fatigue propagation under fully out-of-phase loading is less sensitive to specimen geometry. Therefore, the final geometry was chosen considering the required biaxial loading ratio under in-phase loading.

Optimization of a cruciform specimen for fatigue crack growth under in and out-of-phase in-plane biaxial loading conditions