Creep and Fatigue Life Prediction of Bulk-Polymerized Spliced Acrylic

To evaluate the creep and fatigue fracture lives of structural acrylic spliced components fabricated via bulk polymerization, and to elucidate the associated fracture mechanisms, this study conducted creep and fatigue tests on spliced coupons annealed at 85 °C and 65 °C, as well as base material coupons. The experimental life data were fitted using log-log linear regression models. Based on statistical analysis, a simple yet robust statistical framework was established for life prediction, featuring three design curves: 97.7% survival curves, improved 95% confidence interval lower bounds, and one-sided tolerance curves. Fractographic examination using scanning electron microscopy (SEM) was performed to characterize macroscopic failure modes. The results indicate distinct threshold behavior between stress levels and both creep and fatigue life. The creep threshold stresses are 25 MPa for the base material, 29 MPa for the spliced coupons annealed at 85 °C, and 17 MPa for the spliced coupons annealed at 65 °C. Corresponding fatigue threshold stress amplitudes are 21 MPa, 22 MPa, and 31 MPa, respectively. Failure in the base material is primarily initiated by randomly distributed internal defects, whereas failure in the spliced coupons is mainly caused by defects within the seam or interfacial tearing.