PSI - Issue 76

Available online at www.sciencedirect.com

ScienceDirect

Procedia Structural Integrity 76 (2026) 82–88

© 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the FDMD 2025 chairpersons Keywords: Residual stress profile; Martensitic stainless steel sheet; Very high cycle fatigue; Non-metallic inclusions; Mean-stress sensitivity Abstract The fatigue strength of high-strength steels is significantly affected by residual stresses because of their pronounced mean stress sensitivity. Failing to consider the potential effect of residual stresses when evaluating fatigue data can lead to misinterpretations with serious implications for the design and reliability of components. Therefore, it should be standard practice to either remove residual stresses in fatigue test specimens – for instance, through electropolishing or stress-relief annealing – or quantify them appropriately. This is especially important in very high cycle fatigue (VHCF) studies, where failure beyond 10 7 cycles typically originates from interior defects. In such cases, the distribution of residual stresses within the material is of utmost importance. In the present study, VHCF data obtained with a martensitic stainless steel sheet are evaluated. Residual stress profiles were measured using X-ray diffraction, and the results were corrected to account for the incremental material layer removal during the measurement. It is demonstrated that VHCF failure originated solely at non-metallic inclusions located in a tensile residual stress field. This emphasises the importance of appropriate mean-stress corrections for reliable fatigue strength predictions. 5th International Symposium on Fatigue Design and Material Defects FDMD 2025 Influence of residual stress profile on the very high cycle fatigue properties of a martensitic stainless steel sheet Christina Mamagkinidou a, *, Afshin Khatammanesh a , Stefan Marsoner b , Hans-Peter Gänser b , Martin Rester c , Maximilian Prunbauer c , Michael Proschek c , Bernd M. Schönbauer a, * a Christian Doppler Laboratory for Defect Tolerance of Steels in the High and Very High Cycle Fatigue Regime, Institute of Physics and Materials Science, Department of Natural Sciences and Sustainable Resources, BOKU University, Peter-Jordan-Strasse 82, 1190 Vienna, Austria b Materials Center Leoben Forschung GmbH, Vordernberger Strasse 12, 8700 Leoben, Austria c Berndorf Band GmbH, Corporate Research and Innovation, Leobersdorfer Str. 26, 2560 Berndorf, Austria

* Corresponding authors. Tel.: +43-1- 47654 89216. E-mail address: christina.mamagkinidou@boku.ac.at, bernd.schoenbauer@boku.ac.at

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the FDMD 2025 chairpersons 10.1016/j.prostr.2025.12.290