The push–pull fatigue characteristics of the peak-aged Mg–0.2Zn–0.5Zr alloys with different addition levels of neodymium (Nd) have been investigated. The fatigue strength (σf) of the Mg–xNd–0.2Zn–0.5Zr (NZx0K) alloy increases proportionally with the increase of the Nd content (C Nd) as follows: σf (T6) ≈ (13.8–14.0) C Nd + 46 (for x between 0 and 3.0 wt%). The cyclic stress amplitude also increases but the plastic strain value decreases with the increase of the Nd content. The studied alloys exhibit the strain hardening followed by cyclic softening during fatigue test. During the low-cycle fatigue (LCF) test, the cracks originate from the cyclic deformation and cumulative damage. In high-cycle fatigue (HCF), the failure is due to the cyclic deformation and damage irreversibly caused by environment-assisted cyclic slip. The LCF lives of the alloys fitted well with the Coffin–Manson relation and Basquin laws, the three-parameter equation, and the energy-based concepts. The developed multi-scale fatigue (MSF) life models can be used to predict the LCF and HCF lives of the alloys. Among these models, the MSF life can well capture the influence of Nd addition on fatigue.

Fatigue life is a random variable. Thus, the reliability of a conservative fatigue life prediction for a component in the helicopter dynamic system needs to be substantiated. A standard analytical substantiation method uses averaged manoeuvre loads instead of seeing manoeuvre loads as a random variable whose distribution is estimated with limited precision. This simplification may lead to inaccuracies. A new simulation-based method is developed to conservatively predict fatigue life, while also accounting for the full random distribution and uncertainty of manoeuvre loads. Both methods fully account for uncertain fatigue strength but assume that the mission profile is known or can at least be conservatively estimated. Simulations under synthetic but realistic engineering conditions demonstrate that both methods may be used for accurate substantiation of conservative fatigue life predictions. The simulations also demonstrate that, under the tested conditions, uncertainties from manoeuvre loads may be neglected in fatigue life substantiations as the resulting error is not significant with respect to uncertainties in component fatigue strength.

The economic challenge for PSA regarding the maintenance of their mould foundry park isto predict and improve its lifespan in preventing any risk of initiation and propagationof cracks in thermal fatigue. A method for assessing the number of cycles of castingtooling thermal fatigue used by PSA was developed using the criterion of Fatemi-Socie [A.Fatemi, D. Socie, Fatigue Fract. Engng.Mater. Struct. 11 (1988) 149-165, D.F.Socie, multiaxial fatigue damage models, ASME 109 (1987)293-298], associated with a shear failure mode, which predicts the thermal fatigue damageby assessing stress and strain tensors on different facets around any material point.

Because of the importance of lightweight constructions, nowadays other materials are moreand more substituting components which had previously been made of metals. The usage ofshort fiber-reinforced plastics instead of metals seems self-evident in many cases becauseof their high specific strength and the favorable manufacturing processes. For fatiguelife prediction a simulation process was established, which takes into account the fiberorientation and distribution as a result of an injection molding simulation. Hypothesesfor fatigue life prediction of orthotropic materials have been derived from a lot of testson specimens, implemented in the standard fatigue software tool FEMFAT and verified so farwith component tests.