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A Data-Physics Hybrid Approach for Multiaxial Fatigue Life Prediction of Ti-6Al-4V Alloy
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Xingyue Sun1, Yunyu Liu1, Yu'e Ma1, **, Weihong Zhang2
Chinese Journal of Solid Mechanics | 2025, 46(5) : 571 - 588
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Chinese Journal of Solid Mechanics | 2025, 46(5): 571-588
Research Papers
A Data-Physics Hybrid Approach for Multiaxial Fatigue Life Prediction of Ti-6Al-4V Alloy
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Xingyue Sun1, Yunyu Liu1, Yu'e Ma1, **, Weihong Zhang2
Affiliations
  • 1School of Aeronautics, Northwestern Polytechnical University, Xi'an, 710072
  • 2School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072
Published: 2025-10-27 doi: 10.19636/j.cnki.cjsm42-1250/o3.2025.032
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With the increasing deployment of additively manufactured Ti-6Al-4V in aerospace and other high-performance structural applications, reliable prediction of fatigue life under complex multiaxial loading has become essential for safe design and lifecycle management. However, conventional data-driven approaches often lack predictive accuracy and physical consistency on small datasets and non-proportional multiaxial stress states, limiting their generalizability and interpretability. To address these limitations, this work computes the Mises equivalent stress directly from experimental loading histories and incorporates a Basquin-model-based theoretical fatigue life as prior physics knowledge. Building on this prior, we propose a residual connection-based physics-informed neural network (PI-Res) that learns only the datadriven residual relative to the theoretical life, thereby merging mechanistic fidelity with statistical adaptability. Using laser powder bed fusion (L-PBF) Ti-6Al-4V as the case material, we conduct a systematic comparison against representative purely data-driven baselines—artificial neural networks, random forests, and support vector regression—as well as three canonical data-physics fusion strategies: physics-informed feature engineering, physics-informed loss functions, and physics-informed residual connections. Across multiaxial loading scenarios and distinct life regimes, the PI-Res framework consistently demonstrates superior predictive accuracy alongside stronger adherence to physical trends implied by the stress-life relationship. Moreover, by anchoring the learning process to a mechanistic prior and delegating only the unexplained variance to the network, PI-Res improves robustness under data scarcity and enhances interpretability of model behavior. These findings indicate that residual-style injection of domain knowledge offers a principled pathway to reconcile small-sample constraints with mechanistic coherence in fatigue modeling. Practically, the proposed approach provides a reliable tool to support fatigue life assessment, design margins, and maintenance scheduling for additively manufactured components. Theoretically, it illustrates a transferable physics-data fusion paradigm that can be extended to other material systems and generalized multiaxial fatigue problems where integrating prior physics with flexible learners is crucial.

multiaxial fatigue  /  life prediction  /  Ti-6Al-4V  /  physics-informed  /  machine learning
Xingyue Sun, Yunyu Liu, Yu'e Ma, Weihong Zhang. A Data-Physics Hybrid Approach for Multiaxial Fatigue Life Prediction of Ti-6Al-4V Alloy[J]. Chinese Journal of Solid Mechanics, 2025 , 46 (5) : 571 -588 . DOI: 10.19636/j.cnki.cjsm42-1250/o3.2025.032
Year 2025 volume 46 Issue 5
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doi: 10.19636/j.cnki.cjsm42-1250/o3.2025.032
  • Receive Date:2025-09-30
  • Online Date:2026-03-20
  • Published:2025-10-27
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  • Received:2025-09-30
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    1School of Aeronautics, Northwestern Polytechnical University, Xi'an, 710072
    2School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072
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表12种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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