Interaction of Load Path and Forming-Induced Ductile Damage on the Fatigue Capability of Full-Forward Rod-Extruded Case-Hardening Steel 16MnCrS5

The increasing impact of climate change and resource scarcity demands energy-efficient and resource-conserving manufacturing strategies. Metal forming offers substantial potential for lightweight construction and material efficiency. Forming-induced ductile damage, particularly void nucleation and growth, is often neglected in component design. Industrial practice still relies mainly on macroscopic mechanical properties and safety factors, while microstructural damage evolution and its influence on fatigue performance are largely disregarded. This study investigates load-path-dependent fatigue behavior and damage mechanisms using axial and combined axial–torsional fatigue tests. Particular attention is given to the phase shift d between axial and torsional loading, which strongly affects fatigue life. The results indicate that axial loading dominates damage evolution, while load path interactions significantly change fatigue performance. A phase shift of d = 90° resulted in a significant increase in the number of cycles to failure, Nf, for different total strain amplitudes with the same rotational angle amplitude of θ = 10°. These findings highlight the importance of considering load-path-sensitive stress states in fatigue assessment of formed components. Fractographic analyses, AI-assisted 3D reconstruction, and confocal laser scanning microscopy support the experimental results.