Sarcouncil Journal of Engineering and Computer Sciences

Abstract: This research develops a stress-based life prediction framework for pipelines subjected to cyclic loading, incorporating the interactive effects of residual stresses, dents, and gouges. Pipelines are critical infrastructures whose integrity is challenged by mechanical loading, material imperfections, and operational conditions. Traditional studies often address single defects in isolation; however, this study emphasizes the compounding effects of combined residual stresses and dent–gouge interactions on fatigue life. Using mathematical modeling, S–N curves, Paris’ Law, and Miner’s rule, combined with finite element analysis (FEA) simulations, the study demonstrates that tensile residual stresses accelerate crack initiation and growth, whereas compressive residual stresses extend fatigue life. Results also confirm that gouges are more detrimental than dents, but their combined interaction produces a non-linear reduction in service life by several orders of magnitude. The framework provides a more realistic prediction tool for fatigue life estimation, bridging theoretical modeling and industrial application. It offers actionable recommendations for asset integrity management (AIM), including enhanced inspection protocols, defect prioritization, and optimized maintenance strategies. This contribution addresses a critical gap in the literature by unifying stress analysis, defect interaction, and fatigue modeling, thereby advancing both scientific understanding and practical pipeline reliability.