As high bypass ratio turbofan aero-engines develop towards longer service life and higher reliability, the mechanical property testing and characterization of materials have become the key to ensuring their long-term reliable operation. This paper systematically reviews the progress in the testing technologies, damage characterization and service life prediction of aeroengine materials for long-life design, mainly focusing on three typical scenarios: very-high cycle fatigue of rotor blade materials, long-term high-temperature creep of turbine hot-end components and fatigue crack characterization of real process defect-limited-life materials. It introduces the application of technologies such as very-high-frequency vibration fatigue based on electromagnetic vibration tables, creep measurement based on DIC methods, creep life prediction based on segmented models/physical mechanisms and in-situ fatigue based on SEM/CT in this field. In the future, it is necessary to further study the physical mechanisms of very-high cycle fatigue crack initiation, long-life creep rate stress dependence and microstructure evolution and real process defect damage evolution of aeroengine materials. Meanwhile, it is necessary to further promote intelligent life prediction models based on transfer learning, reinforcement learning, attention mechanisms and so on to achieve an integrated evaluation of the microstructure-performance-life of aero-engine components, in order to meet the continuous challenges brought by future aero-engines.

Fatigue tests were conducted on FGH96 flat plates containing a hole at 600 ℃. Utilizing a viscoplastic constitutive model, the stress and plastic strain distributions within these plates were meticulously calculated. Scanning electron microscopy（SEM） was employed to analyze the fatigue failure mechanism. Based on SEM observations and the geometric attributes of the FGH96 plates with holes, the critical fatigue damage and stress concentration coefficient were defined. Subsequently, the CDM（cumulative damage model）was refined accordingly. The findings revealed that, in comparison to conventional fatigue life prediction techniques, the revised CDM model, which incorporates critical fatigue damage and stress concentration coefficients, exhibited enhanced prediction accuracy for the fatigue life of FGH96 flat plates with holes. Notably, all prediction results fell within a ±2 error band.