Effect of laser-generated component-integrated material sensors on component fatigue strength

The influence of a material sensor in the component’s surface layer on its fatigue strength is investigated by FE simulation. A material model for metastable austenite transformation to martensite from literature is adapted to include effects significant to this scenario. Sensor operation is simulated for single overloads and load cycles and a fatigue assessment is carried out. The detrimental effect on component life stems from the neutralization of the mean compressive stress from shot peening by sensor manufacture and a notch effect during sensor triggering. A straightforward approach for incorporating the effect of the material sensor into component design with worst-case assumptions is presented. The adverse effect can be averted or minimized by appropriate positioning of the sensor.