Fatigue crack growth studies require models that accurately predict component life with low uncertainty. Despite the large number of proposed models, there is no clarity on their applicability, which justifies a comparative analysis between some of them. The dual boundary element method (DBEM) was applied for cracked bodies, whereby the stress intensity factors (SIF), the growth rate, and the number of cycles were computed. Three crack increment models were studied under constant amplitude fatigue loads: the Paris, the Klesnil-Lucas, and the Forman models. Results were validated with experimental literature and through the finite element method, indicating that each model represents a specific zone of the crack growth curve. Klesnil-Lucas model reproduces the region near the fracture threshold, Paris fits the controlled crack growth zone, whereas Forman’s model recreates the unstable fracture zone, i.e., when the stress intensity factor approaches the material’s fracture toughness. The J-integral with stress field decomposition gave errors below 0.8% for mode I. Results were similar for the propagation path and the number of cycles to those obtained with the finite element method, with errors of about 3% considering different K-effective approaches. Klesnil-Lucas accurately predicts the number of cycles with an error margin below 3%, considering the curved region in the growth rate at the propagation onset, while the Paris model becomes very conservative, predicting values up to 50% lower than experimental data. The Klesnil-Lukas model is advised for simulating the entire crack propagation.

This work focusses on the crack growth behaviour of the compact tension specimen under mixed-mode loading, and numerical investigation using ANSYS Mechanical APDL 19.2 extended finite element software with different loading angles. The fatigue life is predicted under constant amplitude fatigue loading using the Paris’ law. The predicted values of the fatigue life in the present study provide consistency with the experimental and numerical results. In addition, the study showed that the direction of crack growth follows the same literature trend of experimental results. According to the results of the crack growth path, there is no effect of changing the geometries thicknesses on the crack growth trajectory. Its only effect is the resistance to higher plastic deformation which decreases as the thickness increases.

Fatigue crack growths of a corner crack emanating from a pinhole of a solid cylinder subjected to cyclic torsion loading were simulated using a Dual-Boundary Element Method (DBEM) based software. For a given crack aspect ratio a/c, larger Mode I stress intensity factor (SIF) was observed at a larger pinhole diameter. Any given initial crack aspect ratio a/c would evolve towards unity. The final evolving crack aspect ratio a/c was shown to be larger than 1. For the same given initial crack length a, a smaller crack depth c was found to result in a shorter fatigue life. A shorter fatigue life yielded a larger orientation angle of the crack growth path.