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Cast parts usually inherit internal defects such as micro shrinkage pores due to the manufacturing process. In order to assess the fatigue behaviour in both finite-life and long-life fatigue regions, this paper scientifically contributes towards a defect-based fatigue design model. Extensive fatigue and fracture mechanical tests were conducted whereby the crack initiating defect size population was fractographically evaluated. Complementary in situ X-ray computed tomography scans before and during fatigue testing enabled an experimental estimation of the lifetime until crack initiation, acting as a significant input for the fatigue model. A commonly applied fatigue assessment approach introduced by Tiryakioglu was modified by incorporating the long crack threshold value, which additionally enabled the assessment of the fatigue strength in the long-life fatigue regime. The presented design concept was validated utilising the fatigue test results, which revealed a sound agreement between the experiments and the model. Only a minor deviation of up to about five percent in case of long-life fatigue strength and up to about 9% in case of finite-lifetime were determined. Thus, the provided extension of Tiryakioglu’s approach supports a unified fatigue strength assessment of cast aluminium alloys in both the finite- and long-life regimes.

As bonded composite repairs are gaining importance for modern civil aircraft, it is necessary to investigate such repairs in detail under relevant environmental conditions. In this work, X-ray computed tomography (XCT) was performed on bonded repairs for carbon fiber (CF) reinforced epoxy matrix composites before and after cyclic conditioning between dry/cold and hot/wet conditions. In detail, high resolution XCT scans in absorption contrast (AC) mode as well as Talbot-Lau grating interferometer (TLGI)-XCT scans to obtain additional differential phase contrast (DPC) and dark-field contrast (DFC) modalities were performed. The repair bonds' constituents could be identified by the high resolution XCT scans. Additional information about fiber alignment, at least of the fiber bundles, could be extracted from the TLGI-XCT scans. In order to gain detailed information on certain specimen features, specimen dimensions were reduced for additional high resolution XCT scans.