Fretting fatigue performance and life prediction of GH4169/FGH96 arc dovetail joints at high temperature

To address the challenges associated with fretting fatigue in aeroengine components, this study proposes a comprehensive analysis framework based on multiaxial damage criteria. The mechanical behavior of GH4169 arc dovetail joints is systematically investigated, and a corresponding life prediction model is developed. High-temperature fretting fatigue experiments, combined with multiple characterization techniques, are employed to acquire data on relative displacement, fracture morphology, surface wear, and elemental composition, thereby enabling an in-depth understanding of the damage evolution process. A three-dimensional finite element model of the arc dovetail structure is constructed, incorporating the Chaboche constitutive model to accurately capture stress-strain responses in critical regions of the tenon. A customized post-processing routine is implemented to visualize the multiaxial damage field. Based on the resulting damage distribution, a gradient-corrected life prediction method is proposed. The results indicate that the arc dovetail joint design effectively alters the stress distribution, thereby reducing fretting fatigue damage. Moreover, the proposed life prediction method demonstrates good physical relevance and prediction accuracy.