Acoustic emission multiplets as early warnings of fatigue failure in metallic materials

Fatigue, i.e. the failure of mechanical structures under cycling loading, remains a considerable technological challenge as it occurs unexpectedly when the structure is operating apparently in a safe and steady state regime, without external signs of mechanical deterioration. Here we report for the first time, in different metallic materials, the detection of acoustic emissions specific of fatigue crack growth. These so-called acoustic multiplets are characterized by nearly identical waveforms, signature of a unique source, are repeatedly triggered over many successive loading cycles at the same stress level, and originate from a single location. They mark the slow, incremental propagation of a fatigue crack at each cycle, or the rubbing along its faces. Being specific to fatigue cracking, they can be used as early warnings of crack propagation, which will ultimately lead to structural failure. Their detection and characterization thus open the way towards a new, reliable monitoring of the onset of fatigue cracking during mechanical tests or within structures in service.