It is shown that acoustic second harmonic generation is a useful tool for studying surface microcrack development during fatigue of a high‐strength aluminum alloy. A fundamental (5 MHz) surface acoustic wave (SAW) was transmitted across the gauge section of flexural fatigue specimens of Al 7075‐T6. The second harmonic amplitude was determined after several increments of fatigue, as a function of external load and the amplitude of the fundamental. It was found that the second harmonic signal is at a maximum close to zero external load and increases with progressing fatigue. Harmonic generation, attributable to microcracking at the surface, has been observed as early as 10–20% of the expended fatigue life. A simple analysis to obtain a coefficient of harmonic‐generation efficiency versus applied surface stress is described. This analysis considers the effect of changes in attenuation of the fundamental and harmonic waves associated with degree of surface microcrack opening as a function of surface stress. It is shown that acoustic harmonic generation may be a useful tool for reliable monitoring of the state of fatigue of a structural material.
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