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Abstract. This paper presents a review of the conservatism approaches applied by different industrial sectors to the stress-life (S-N) analysis of 'life-limited' or 'safe-life' components. A comparison of the fatigue design standards for 6 industrial sectors identified that the conservatism approaches are highly inconsistent when comparing the areas of variability and uncertainty accounted for along with the conservatism magnitude and method of application. Through the use of a case-study based on the SAE keyhole benchmark and 4340 steel S-N data, the industrial sector which introduces the greatest reduction of a component life-limit was identified as the nuclear sector. The results of the case-study also highlighted that conservatism applied to account for scatter in S-N data currently provides the greatest contribution to the reduction of component life-limits.

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The volume manufacture of power-dense electrical machines results in a random conductor lay throughout the stator winding and stator slots, which is unknown and varies from slot-to-slot. The AC losses of such windings are sensitive to the specific conductor lay present within the stator slot. However, limited data is currently available regarding the actual conductor lay observed in 'asmanufactured' windings. This paper presents the novel application of X-ray Computed Tomography to characterize the conductor lay in a wound prototype plastic stator. Preliminary results indicate that limited strand transposition occurs in the stator active length, compared to the significant strand transposition present in the end winding region. Variability in strand compaction in the stator slot is also identified as a contributary factor to the variability observed in AC losses.