AbstractThe present study aims to assess the additional fatigue life enhancement obtained by coldworking a previously cold expanded plate hole. Two different methods of performing the second coldworking were considered, i.e. moving the mandrel in the same direction as for the first coldworking or moving it in the opposite direction. A three dimensional finite element analysis for establishing the residual stress field induced by two successive coldworkings (5.58% then 4.8%) was carried out. Al 7475‐T7351 specimens with a central hole were cold expanded at 5.58%, subjected to cyclic loading at constant amplitude for a predetermined life fraction (on the basis of 5.58% cold expanded hole fatigue life) and then re‐coldworked at 4.8%. After this rework, the specimens were again subjected to the same fatigue loading conditions until failure. During cycling, the fatigue crack extension was monitored using a video‐camera in order to determine the coldworking effect on both the initiation period and the propagation life.The fatigue test results have shown that a second coldworking may enhance the fatigue life of an already coldworked hole. For a given cyclic loading level, the beneficial effect depends upon the applied life fraction before reworking. The direction of the mandrel movement during the second coldworking has no noticeable influence on the additional fatigue life improvement. These experimental results have been analyzed with reference to the calculated residual stress