High-accuracy fatigue life prediction and early fracture warning for ferromagnetic metals via spin correlation amplification

Sudden fatigue failure of metallic structures triggers thousands of safety accidents annually, causing tens of thousands of casualties and economic losses approaching $100 billion. Traditional detection techniques face challenges in capturing early fatigue damage features like subnanometer atomic displacements and localized metal bond ruptures. Based on the synchronized weakening mechanism between binding forces and exchange interactions during fatigue processes in ferromagnetic metals, this study obtained high-sensitivity fatigue observations by exciting the quantum spin correlation amplification effect via an external magnetic field. We conducted fatigue tests on 193 ferromagnetic metal samples over 3700 cumulative hours, establishing a mapping relationship between fatigue-induced magnetic flux changes and the degree of binding force weakening. This work integrated macroscopic fatigue life prediction with ferromagnetic material microstructural parameters, achieving a prediction accuracy with R² > 0.9 and providing a reliable prefracture warning, potentially mitigating fatigue fractures in large-scale engineering structures and reducing the associated economic losses.