The Manson-Halford (M-H) nonlinear cumulative damage model is widely applied for fatigue life analysis problems under multi-level loading. In this model, the influence of loading sequence on the fatigue life can be better considerer, but the loading interaction effect is ignored. An improved whale optimization algorithm (IWOA) by integrating multiple strategies is proposed. The ability of global search and local exploitation is balanced and improved through nonlinear convergence factor, adaptive weighting factors and the Cauchy reverse learning strategies. In order to fully account for loading interaction effect, loading weighting factors are introduced to modify the M-H model, and the parameters are optimized through the global search properties of IWOA. The model is evaluated on multi-level loading fatigue experimental data from five metal materials and two aluminum alloy welded joints. The results suggest that the proposed IWOA has better optimization accuracy compared to the standard whale optimization algorithm (WOA). The proposed modified M-H model has better prediction performance compared to the four traditional cumulative damage models, which can be effectively applied to multi-level loading fatigue life analysis problems under actual working conditions. The proposed model is useful for the study of fatigue life evaluation methods.
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