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Crystal plasticity modeling of low-cycle fatigue in 6061-T6 aluminum alloy.

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Title: Crystal plasticity modeling of low-cycle fatigue in 6061-T6 aluminum alloy.
Authors: Hu, Junsong1 (AUTHOR), Deng, Ruijie2 (AUTHOR), Wang, Pan3 (AUTHOR) wangpan0623@csu.edu.cn
Source: Applied Mathematics & Mechanics. Jun2026, Vol. 47 Issue 6, p1323-1340. 18p.
Subjects: Material plasticity, Dislocation density, Crack initiation (Fracture mechanics), Fatigue life, Crystal grain boundaries, Finite element method, Intermetallic compounds, Aluminum alloys
Abstract: The 6061-T6 aluminum alloy is widely used in structural components under cyclic loading. This study investigates the low-cycle fatigue (LCF) behavior of this alloy through strain-controlled experiments combined with a multiscale crystal plasticity finite element (CPFE) framework. The fatigue crack nucleation life constituted a nearly consistent fraction of total life over the investigated strain amplitudes. A thermally activated slip-based model incorporating dislocation density as an internal state variable was implemented by backward Euler discretization and accurately reproduced experimental hysteresis loops. The CPFE simulations show that increasing strain amplitudes accelerates dislocation accumulation, with pile-ups preferentially occurring in regions of high grain boundary density. Orientation-dependent grain responses generate stress gradients and strain incompatibilities that promote crack initiation, while the peak accumulated equivalent plastic strain consistently localizes near grain boundaries. An extreme value statistical approach using the accumulated equivalent plastic strain as the fatigue indicator parameter (FIP) successfully predicts fatigue lives in agreement with experimental data. The simulations including brittle iron-rich intermetallic particles further reveal that particle-matrix property mismatch induces strong interfacial stress concentrations, where dislocation pile-ups trigger localized plasticity and preferential crack initiation. These multiscale simulations provide valuable insights for the structural integrity assessment and microstructure-informed design of fatigue-resistant aluminum alloys. [ABSTRACT FROM AUTHOR]
Copyright of Applied Mathematics & Mechanics is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Crystal plasticity modeling of low-cycle fatigue in 6061-T6 aluminum alloy.
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  Data: <searchLink fieldCode="AR" term="%22Hu%2C+Junsong%22">Hu, Junsong</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Deng%2C+Ruijie%22">Deng, Ruijie</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Pan%22">Wang, Pan</searchLink><relatesTo>3</relatesTo> (AUTHOR)<i> wangpan0623@csu.edu.cn</i>
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  Data: <searchLink fieldCode="JN" term="%22Applied+Mathematics+%26+Mechanics%22">Applied Mathematics & Mechanics</searchLink>. Jun2026, Vol. 47 Issue 6, p1323-1340. 18p.
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  Data: <searchLink fieldCode="DE" term="%22Material+plasticity%22">Material plasticity</searchLink><br /><searchLink fieldCode="DE" term="%22Dislocation+density%22">Dislocation density</searchLink><br /><searchLink fieldCode="DE" term="%22Crack+initiation+%28Fracture+mechanics%29%22">Crack initiation (Fracture mechanics)</searchLink><br /><searchLink fieldCode="DE" term="%22Fatigue+life%22">Fatigue life</searchLink><br /><searchLink fieldCode="DE" term="%22Crystal+grain+boundaries%22">Crystal grain boundaries</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br /><searchLink fieldCode="DE" term="%22Intermetallic+compounds%22">Intermetallic compounds</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloys%22">Aluminum alloys</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: The 6061-T6 aluminum alloy is widely used in structural components under cyclic loading. This study investigates the low-cycle fatigue (LCF) behavior of this alloy through strain-controlled experiments combined with a multiscale crystal plasticity finite element (CPFE) framework. The fatigue crack nucleation life constituted a nearly consistent fraction of total life over the investigated strain amplitudes. A thermally activated slip-based model incorporating dislocation density as an internal state variable was implemented by backward Euler discretization and accurately reproduced experimental hysteresis loops. The CPFE simulations show that increasing strain amplitudes accelerates dislocation accumulation, with pile-ups preferentially occurring in regions of high grain boundary density. Orientation-dependent grain responses generate stress gradients and strain incompatibilities that promote crack initiation, while the peak accumulated equivalent plastic strain consistently localizes near grain boundaries. An extreme value statistical approach using the accumulated equivalent plastic strain as the fatigue indicator parameter (FIP) successfully predicts fatigue lives in agreement with experimental data. The simulations including brittle iron-rich intermetallic particles further reveal that particle-matrix property mismatch induces strong interfacial stress concentrations, where dislocation pile-ups trigger localized plasticity and preferential crack initiation. These multiscale simulations provide valuable insights for the structural integrity assessment and microstructure-informed design of fatigue-resistant aluminum alloys. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
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  Data: <i>Copyright of Applied Mathematics & Mechanics is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s10483-026-3400-6
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      – Code: eng
        Text: English
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        PageCount: 18
        StartPage: 1323
    Subjects:
      – SubjectFull: Material plasticity
        Type: general
      – SubjectFull: Dislocation density
        Type: general
      – SubjectFull: Crack initiation (Fracture mechanics)
        Type: general
      – SubjectFull: Fatigue life
        Type: general
      – SubjectFull: Crystal grain boundaries
        Type: general
      – SubjectFull: Finite element method
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      – SubjectFull: Intermetallic compounds
        Type: general
      – SubjectFull: Aluminum alloys
        Type: general
    Titles:
      – TitleFull: Crystal plasticity modeling of low-cycle fatigue in 6061-T6 aluminum alloy.
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            NameFull: Hu, Junsong
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            NameFull: Deng, Ruijie
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            – D: 01
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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