On the life‐controlling microstructural fatigue mechanisms in ductile metals and alloys in the gigacycle regime

The high‐cycle fatigue (HCF) behaviour of ductile metals and alloys, and the life‐controlling microstructural fatigue mechanisms known from HCF are reviewed critically with respect to their possible role in the gigacycle or ultra‐high‐cycle fatigue (UHCF) regime. Arguments are presented to support the hypothesis that, at the very low amplitudes of the UHCF regime, fatigue crack initiation, resulting from cyclic strain localization, and slow early Stage I fatigue crack propagation are the life‐controlling mechanisms and that these processes can essentially be described in terms of the microstructurally irreversible portion of the cumulative cyclic plastic strain. Emphasis is placed on the important role of the so‐called slip irreversibility which decreases as the amplitude becomes lower and lower. Finally, the Manson–Coffin law is reformulated for very low amplitudes in terms of microstructurally relevant parameters, and a fatigue life diagram is developed, based on these preceding microstructural considerations. Important features of this diagram are: (i) the plastic strain fatigue limit in the HCF regime which is related to the threshold for cyclic strain localization in persistent slip bands; and (ii) the transition from this plastic strain fatigue limit to a threshold of negligible slip irreversibility at still lower amplitudes in the UHCF regime.