Ultrasonic Fatigue Testing of Structural Steel S275JR+AR with Insights into Corrosion, Mean Stress and Frequency Effects

There are limited experimental data on VHCF for structural steels for > [Formula: see text] cycles. Unalloyed low-carbon steel S275JR+AR is a common structural material for the heavy machinery in minerals, sand and aggregate applications. The purpose of this research is to investigate the fatigue behaviour in the gigacycle domain (> [Formula: see text] cycles) for S275JR+AR grade steel. This is achieved using accelerated ultrasonic fatigue testing in as-manufactured, pre-corroded and non-zero mean stress conditions. As internal heat generation is a massive challenge for ultrasonic fatigue testing of structural steels which exhibit a pronounced frequency effect, effective temperature control is crucial for implementation of testing. The frequency effect is assessed by comparing the test data at 20 kHz and 15–20 Hz. Its contribution is significant, as there is no overlap between the stress ranges of interest. The obtained data are intended to be applied to the fatigue assessments of the equipment operating at the frequency for up to [Formula: see text] cycles over years of continuous service.