Fatigue life estimation of additively manufactured Ti-6Al-4V: Sensitivity, scatter and defect description in Damage-tolerant models

Macallister, Nicolas; Becker, Thorsten Hermann

doi:10.1016/j.actamat.2022.118189

Cited by 37 publications

(18 citation statements)

References 59 publications

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“…It is seen that there is a defect‐enriched layer near the surface for both as‐built and surface‐polished specimens. Note that similar results were reported in Macallister and Becker 39 . The values of thickness of the defect‐enriched layer ( T ) were measured via image‐Pro Plus 6.0 software to get T = 150 μm and T = 120 μm for the as‐built and surface‐polished specimens, respectively.…”

Section: Resultssupporting

confidence: 55%

“…Note that similar results were reported in Macallister and Becker. 39 The values of thickness of the defect-enriched layer (T) were measured via image-Pro Plus 6.0 software to get T = 150 μm and T = 120 μm for the as-built and surface-polished specimens, respectively. In order to quantitatively characterize the defect size distribution within the defect-enriched layer, the sizes of the defects observed on the fracture surfaces of failed specimens were measured by the use of Image-Pro Plus 6.0 software.…”

Section: Surface States Of L-pbf Ti-6al-4vmentioning

confidence: 99%

“…On the other hand, some studies have shown that heat‐treatment processes such as hot isostatic pressing (HIP) may be applied to diminish the internal defects so as to enhance the fatigue performance of L‐PBF Ti‐6Al‐4V, but it is almost impossible to reduce the amount of surface defects 35–37 . Hence, many studies have been carried out to investigate the effect of surface roughness on the fatigue properties of L‐PBF alloys 38–40 . However, the effect of surface roughness on the fatigue behavior of L‐PBF Ti‐6Al‐4V up to VHCF regime under as‐built surface condition is rarely reported and the related crack initiation mechanism is still unclear.…”

Section: Introductionmentioning

confidence: 99%

“…[35][36][37] Hence, many studies have been carried out to investigate the effect of surface roughness on the fatigue properties of L-PBF alloys. [38][39][40] However, the effect of surface roughness on the fatigue behavior of L-PBF Ti-6Al-4V up to VHCF regime under as-built surface condition is rarely reported and the related crack initiation mechanism is still unclear.…”

Section: Introductionmentioning

confidence: 99%

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High‐cycle and very‐high‐cycle fatigue behavior at two stress ratios of Ti‐6Al‐4V manufactured via laser powder bed fusion with different surface states

Zheng

Zhong

et al. 2023

Fatigue Fract Eng Mat Struct

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The high-cycle fatigue (HCF) and very-high-cycle fatigue (VHCF) behavior of Ti-6Al-4V manufactured by laser powder bed fusion (L-PBF) was investigated to reveal the effects of surface roughness and stress ratio on fatigue performance. Fatigue tests were performed by an ultrasonic vibration machine with a frequency of 20 kHz. The fatigue strength of surface-polished specimens is generally higher than that of as-built specimens in HCF and VHCF regimes.Fatigue cracks initiated from the subsurface of as-built and surface-polished L-PBF Ti-6Al-4V. The values of size and depth for the defects that acted as fatigue crack origins present large scattering for L-PBF Ti-6Al-4V due to the interaction between surface roughness and subsurface defects. For surfacepolished L-PBF Ti-6Al-4V, fatigue cracks have almost the same resistance to propagation at both stress ratios of R = À1 and 0.7. K E Y W O R D Slaser powder bed fusion, stress ratio, surface roughness, Ti-6Al-4V, very-high-cycle fatigue Highlights• Fatigue strength of surface-polished specimens higher than as-built L-PBF Ti-6Al-4V • Fatigue crack initiation from lack-of-fusion defects in subsurface defectenriched layer • Defect & surface roughness with greater effect on crack initiation than stress ratio • Crack propagation much easier in as-built than surface-polished L-PBF Ti-6Al-4V

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Section: Resultssupporting

confidence: 55%

Section: Surface States Of L-pbf Ti-6al-4vmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

High‐cycle and very‐high‐cycle fatigue behavior at two stress ratios of Ti‐6Al‐4V manufactured via laser powder bed fusion with different surface states

Zheng

Zhong

et al. 2023

Fatigue Fract Eng Mat Struct

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“…[189][190][191] Based on this consideration, the defect-based fracture mechanics methods have been successfully employed to predict the fatigue life of AM materials and achieved good results. 37,46,55,[191][192][193][194][195][196][197][198] Many fatigue crack propagation models have been adopted to predict the fatigue life of AM metals. A simply modified version of the Paris equation is as follows:…”

Section: Fracture Mechanics Methodsmentioning

confidence: 99%

Recent developments and future trends in fatigue life assessment of additively manufactured metals with particular emphasis on machine learning modeling

Zhan,

He,

Tang

et al. 2023

Fatigue Fract Eng Mat Struct

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Additive manufacturing (AM) has emerged as a very promising technology for producing complex metallic components with enhanced design flexibility. However, the mechanical properties and fatigue behavior of AM metals differ significantly from conventionally manufactured materials, thereby presenting challenges in accurately predicting their fatigue life. This study provides a comprehensive overview of recent developments and future trends in fatigue life prediction of AM metals, with a particular emphasis on machine learning (ML) modeling techniques. This review recalls recent developments and achievements in fatigue characteristics of AM metals, ML‐based approaches for fatigue life prediction of AM metals, and non‐ML‐based methodologies for the same purpose. In particular, some commonly used regression and classification techniques for fatigue evaluation of AM metals are summarized and elaborated. The study intends to furnish researchers, engineers, and practitioners in the field of AM with a guidance for the accurate and efficient prediction of fatigue life in AM metal components.

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Cyclic R‐Curve Measurements for Structural Metallic Alloys

Patriarca,

D’Andrea,

Cova

et al. 2024

Adv Eng Mater

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Fractures nucleated from defects and subjected to cyclic loading can experience propagation for a range of stress intensity factor ΔK well below the so‐called long crack threshold. This phenomenon is attributed to the development of crack closure mechanisms which may differ from those observed in laboratory tests conducted in accordance with current standards. Cracks originating from material defects require a specific degree of extension to develop the plastic wake, thus achieving a stabilized condition called the long crack threshold. However, in certain materials, this stabilization length can extend up to several millimetres, effectively encompassing a significant portion of the component’s fatigue life. Therefore, understanding and quantifying the development of ΔKth with crack extension is important for implementing a reliable assessment procedure based on the fracture mechanics theory. In this study, R‐curve measurements are presented for five distinct structural metallic alloys widely used in various industrial applications. Additionally, the impact of load ratio is investigated, providing a comprehensive analysis of fatigue crack resistance in terms of the R‐curve concept. This study underscores the necessity of ruling new experimental techniques to measure and implement the long crack threshold, thereby ensuring the development of a reliable and robust framework for fatigue assessment.This article is protected by copyright. All rights reserved.

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Fatigue life estimation of additively manufactured Ti-6Al-4V: Sensitivity, scatter and defect description in Damage-tolerant models

Cited by 37 publications

References 59 publications

High‐cycle and very‐high‐cycle fatigue behavior at two stress ratios of Ti‐6Al‐4V manufactured via laser powder bed fusion with different surface states

High‐cycle and very‐high‐cycle fatigue behavior at two stress ratios of Ti‐6Al‐4V manufactured via laser powder bed fusion with different surface states

Recent developments and future trends in fatigue life assessment of additively manufactured metals with particular emphasis on machine learning modeling

Cyclic R‐Curve Measurements for Structural Metallic Alloys

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