Defects in Electron Beam Melted Ti-6Al-4V: Fatigue Life Prediction Using Experimental Data and Extreme Value Statistics

Sandell, Viktor; Hansson, Thomas; Roychowdhury, Sushovan; Månsson, Tomas; Delin, Mats; Åkerfeldt, Pia; Antti, Marta‐Lena

doi:10.3390/ma14030640

Cited by 17 publications

(8 citation statements)

References 38 publications

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“…Many other researchers also utilized the two methods to estimate the maximum inclusion size in materials, and their estimation of the maximum inclusion size accords well with the experimental results [16][17][18][19][20][21][22][23]. The methods are also successfully applied for defect statistics of additive manufacturing materials and components [24][25][26][27][28]. Size effect in very high cycle fatigue regime is generally analyzed by considering the statistical distribution of the defects originating the fatigue failures within the risk volume.…”

Section: Introductionmentioning

confidence: 85%

Maximum Inclusion Size Evaluation and Fatigue Strength Analysis of 40Cr Structural Steel

Zhao

2022

Material Design & Processing Communications

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Statistics of extreme values (SEV) and generalized Pareto distribution (GPD) are adopted to predict the maximum inclusion size in 40Cr structural steel, and the fatigue strength was estimated according to the obtained maximum inclusion size. The estimated results were compared with the experimental results obtained in rotating bending fatigue testing, where all failure-relevant inclusions of the present study were quantitatively analyzed with respect to area (square root of the projected inclusion area). Both the estimation results are consistent with the experimental results. Furthermore, a suitable maximum inclusion size equal to the prior austenite grain size is proposed for the material manufacturing process.

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Section: Introductionmentioning

confidence: 85%

Maximum Inclusion Size Evaluation and Fatigue Strength Analysis of 40Cr Structural Steel

Zhao

2022

Material Design & Processing Communications

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“…In other cases, when using Ti scaffolds as bone implants, rough surfaces enhance the fixation between an implant and bone. Loose powder on the surface is undesirable and should be removed, e. g. by chemical etching (Sandell et al, 2021). The imperfections may result from both material and process determinants.…”

Section: Issues Associated With the Biomedical Implants Along With Th...mentioning

confidence: 99%

“…A bone implant is usually expected to possess higher mechanical strengths near bone elastic modulus. The long-term successful implantation is determined by its fatigue strength under cyclic loading conditions (Sandell et al, 2021). The mechanical properties are also influenced by the topology, defects, parent material and relative density (Gatto et al, 2021;Sizova et al, 2021).…”

Section: Issues Associated With the Biomedical Implants Along With Th...mentioning

confidence: 99%

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

Ishfaq

Rehman

Khan

et al. 2021

RPJ

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Purpose Human aging is becoming a common issue these days as it results in orthopaedic-related issues such as joints disorderness, bone-fracture. People with age = 60 years suffer more from these aforesaid issues. It is expected that these issues in human beings will ultimately reach 2.1 billion by 2050 worldwide. Furthermore, the increase in traffic accidents in young people throughout the world has significantly emerged the need for artificial implants. Their implantation can act as a substitute for fractured bones or disordered joints. Therefore, this study aims to focus on electron beam melted titanium (Ti)-based orthopaedic implants along with their recent trends in the field. Design/methodology/approach The main contents of this work include the basic theme and background of the metal-based additive manufacturing, different implant materials specifically Ti alloys and their classification based on crystallographic transus temperature (including α, metastable β, β and α + β phases), details of electron beam melting (EBM) concerning its process physics, various control variables and performance characteristics of EBMed Ti alloys in orthopaedic and orthodontic implants, applications of EBMed Ti alloys in various load-bearing implants, different challenges associated with the EBMed Ti-based implants along with their possible solutions. Recent trends and shortfalls have also been described at the end. Findings EBM is getting significant attention in medical implants because of its minor issues as compared to conventional fabrication practices such as Ti casting and possesses a significant research potential to fabricate various medical implants. The elastic modulus and strength of EBMed ß Ti-alloys such as 24Nb-4Zr-8Sn and Ti-33Nb-4Sn are superior compared to conventional Ti for orthopaedic implants. Beta Ti alloys processed by EBM have near bone elastic modulus (approximately 35–50 GPa) along with improved tribo-mechanical performance involving mechanical strength, wear and corrosion resistance, along with biocompatibility for implants. Originality/value Advances in EBM have opened the gateway Ti alloys in the biomedical field explicitly ß-alloys because of their unique biocompatibility, bioactivity along with improved tribo-mechanical performance. Less significant work is available on the EBM of Ti alloys in orthopaedic and orthodontic implants. This study is directed solely on the EBM of medical Ti alloys in medical sectors to explore their different aspects for future research opportunities.

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“…The approaches in Refs. 26 – 28 , on the other hand, exploit the information on the defect population assessed with micro-CT analysis or statistics of Extreme Values and fracture mechanics methodologies to assess the fatigue response of AM parts. Derrick et al 29 proposed a model for estimating the P–S–N curves based on the specimen hardness, roughness and defect size, showing the variation of the fatigue curves with these factors.…”

Section: Introductionmentioning

confidence: 99%

Experimental scatter of the fatigue response of additively manufactured components: a statistical method based on the Profile Likelihood

Tridello,

Boursier Niutta,

Rossetto

et al. 2023

Sci Rep

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The fatigue response of additively manufactured (AM) specimens is mainly driven by manufacturing defects, like pores and lack of fusion defects, which are mainly responsible for the large variability of fatigue data in the S–N plot. The analysis of the results of AM tests can be therefore complex: for example, the influence of a specific factor, e.g. the building direction, can be concealed by the experimental variability. Accordingly, appropriate statistical methodologies should be employed to safely and properly analyze the results of fatigue tests on AM specimens. In the present paper, a statistical methodology for the analysis of the AM fatigue test results is proposed. The approach is based on shifting the experimental failures to a reference number of cycles starting from the estimated P–S–N curves. The experimental variability of the fatigue strength at the reference number of cycles is also considered by estimating the profile likelihood function. This methodology has been validated with literature datasets and has proven its effectiveness in dealing with the experimental scatter typical of AM fatigue test results.

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Defects in Electron Beam Melted Ti-6Al-4V: Fatigue Life Prediction Using Experimental Data and Extreme Value Statistics

Cited by 17 publications

References 38 publications

Maximum Inclusion Size Evaluation and Fatigue Strength Analysis of 40Cr Structural Steel

Maximum Inclusion Size Evaluation and Fatigue Strength Analysis of 40Cr Structural Steel

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

Experimental scatter of the fatigue response of additively manufactured components: a statistical method based on the Profile Likelihood

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