The present paper is focused on an experimental study of the damage-to-failure mechanism of additively manufactured 316L stainless steel specimens subjected to very high cycle fatigue (VHCF) loading. Ultrasonic axial tension-compression tests were carried out on specimens for up to 109 cycles, and fracture surface analysis was performed. A fine granular area (FGA) surrounding internal defects was observed and formed a “fish-eye” fracture type. Nonmetallic inclusions and the lack of fusion within the fracture surfaces that were observed with SEM were assumed to be sources of damage initiation and growth of the FGAs. The characteristic diameter of the FGAs was ≈500 μm on the fracture surface and were induced by nonmetallic inclusions; this characteristic diameter was the same as that for the fracture surface induced by a lack of fusion. Fracture surfaces corresponding to the high cycle fatigue (HCF) regime were discussed as well to emphasize damage features related to the VHCF regime.

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The printability of artificial defects inside the additively manufactured laser powder bed fusion (LPBF) 316L stainless steel is investigated. The printing parameters of the LPBF process are optimized to produce artificial defects with reproducible sizes at desired positions while minimizing redundant porosity. The smallest obtained artificial defect is 90 μm in diameter. The accuracy of the geometry of the printed defect depends on both the height and the diameter in the input model. The effect of artificial defects on the very‐high‐cycle fatigue (VHCF) behavior of LPBF 316L stainless steel is also studied. The specimens printed with artificial defects in the center are tested under VHCF using an ultrasonic machine. Crack initiation is accompanied by the formation of a fine granular area (FGA), typical of VHCF. Despite the presence of relatively large artificial defects, FGA formation is observed around accidental natural printing defects closer to the surface, which can still be considered as internal. The causes for this occurrence are discussed.

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Design of new smart prosthetics or robotic grippers gives a major impetus to low-cost manufacturing and rapid prototyping of force-sensing devices. In this paper, we examine piezoresistive force sensors based on carbon nanotube fibers fabricated by a novel wet pulling technique. The developed sensor is characterized by an adjustable force range coupled with high sensitivity to enable the detection of a wide range of forces and displacements limited by the experimental setup only. We have demonstrated the applicability of the developed unit in tactile sensing, displacement sensing, and nanophone vibration monitoring system and evaluated its force sensing characteristics, i.e. displacement/force input and resistance/mechanical response. In the experiments it measures 0-115 N force range within 2.5 mm displacement. Moreover, the sensor demonstrates good linearity, low hysteresis, and stability when tested over 10 000 cycles. The developed sensor suits multiple applications in the field of soft and transparent sensors, nanophones, actuators, and other robotics devices for both regular and extreme environments, e.g. deep underwater and radioactive environment.