Effect of Burrs on the Fatigue Strength of Metallic Structures: Experimental Study on Open Hole Ti‐6Al‐4V Specimens With Burrs

Santiago Frutos Taravillo; Eric Paroissien; Yann Landon; Sébastien Schwartz; Mathieu Fressinet; Clément Chirol

doi:10.1111/ffe.70283

journal article Apr 09, 2026

Effect of Burrs on the Fatigue Strength of Metallic Structures: Experimental Study on Open Hole Ti‐6Al‐4V Specimens With Burrs

Santiago Frutos Taravillo

Eric Paroissien Yann Landon Sébastien Schwartz Mathieu Fressinet Clément Chirol

Fatigue & Fracture of Engineering Materials & Structures · Wiley

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Abstract

ABSTRACT
One‐Way‐Assembly accelerates aerospace manufacturing but risks leaving drilling burrs at the interfaces of mechanical joints. The detrimental impact of burrs on fatigue strength is widely recognized in the literature, but the mechanisms driving this “knock‐down” remain unclear. This study investigates this phenomenon using open‐hole Ti‐6Al‐4V specimens. The experimental campaign systematically decouples the effects of macrogeometric stress concentration, residual stresses, and burr tip microgeometric features. Results revealed a non‐monotonic relationship between burr size and the fatigue “knock down,” leading to rejecting the macroscopic stress concentration hypothesis. Similarly, stress‐relief heat treatments failed to mitigate the fatigue “knock‐down,” ruling out residual stresses as a governing factor. Instead, a unified failure mechanism was identified. All detrimental configurations collapsed into a single S‐N cluster. Striation counting confirmed this cluster aligns with the material's pure crack propagation behavior, demonstrating that sharp burr tip features severely shorten the crack nucleation phase.

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Details

Published: Apr 09, 2026
License: View

Authors

S

Santiago Frutos Taravillo

Airbus Operations SAS Toulouse France; Institut Clément Ader (ICA) Université de Toulouse Toulouse France

E

Eric Paroissien

Institut Clément Ader (ICA) Université de Toulouse Toulouse France

Y

Yann Landon

Institut Clément Ader (ICA) Université de Toulouse Toulouse France

S

Sébastien Schwartz

Institut Clément Ader (ICA) Université de Toulouse Toulouse France

M

Mathieu Fressinet

Airbus Operations SAS Toulouse France

C

Clément Chirol

Airbus Atlantic Colomiers France

Funding

Airbus

Cite This Article

Santiago Frutos Taravillo, Eric Paroissien, Yann Landon, et al. (2026). Effect of Burrs on the Fatigue Strength of Metallic Structures: Experimental Study on Open Hole Ti‐6Al‐4V Specimens With Burrs. Fatigue & Fracture of Engineering Materials & Structures. https://doi.org/10.1111/ffe.70283

Effect of Burrs on the Fatigue Strength of Metallic Structures: Experimental Study on Open Hole Ti‐6Al‐4V Specimens With Burrs

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