Fatigue analysis of wire arc additive manufactured (3D printed) components with unmilled surface

Bartsch, Helen; Kühne, Ronny; Citarelli, Sandro; Schaffrath, Simon; Feldmann, Markus

doi:10.1016/j.istruc.2021.01.068

Cited by 54 publications

(11 citation statements)

References 29 publications

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“…This short literature review shows that, in the specific case of WAAM, because of an unprecedented roughness that is highly dependent on the deposition strategy, an empirical relationship between stress concentration K t and surface state parameters is yet to be determined. From the study conducted by Bartsch et al, 7 no obvious correlation appears to exist between K t and some selected local geometry variables. To further explore that approach would require highly detailed 3D scans and costly numerical simulations.…”

Section: Introductionmentioning

confidence: 91%

“…An arithmetic average roughness

R_{a}

under

50 normalμ

m to only a few micrometers is typically measured 5,6 . In the case of direct energy deposition (DED) AM techniques, such as WAAM, surface roughness is the result of the geometry's discretization in layers and weld beads; the roughness

R_{a}

can be more than a hundred microns 7,8 . In order to avoid a systematic and complete machining of AM parts, the effect of the as‐built roughness on mechanical properties, especially in fatigue, must be carefully taken into account.…”

Section: Introductionmentioning

confidence: 99%

“…No experimental data was considered to validate the proposed model. In the work of Bartsch et al, 7 a Basquin law is identified on experimental fatigue lives of rough WAAM samples. Based on numerical calculations performed on the digitized roughness profiles of the samples, a stress concentration factor

K_{t}

is determined and associated with the experimental fatigue lives.…”

Section: Introductionmentioning

confidence: 99%

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Thermometric investigations for the characterization of fatigue crack initiation and propagation in Wire and Arc Additively Manufactured parts with as‐built surfaces

Bercelli

Doudard

Calloch

et al. 2022

Fatigue Fract Eng Mat Struct

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Metal Additive Manufacturing (AM) allows for the fabrication of complex shapes with high added value at low costs. Indeed, as‐built structures are near net shape: they require few to no finishing operations. However, as‐built AM parts present significant roughness caused by the layer discretization. In the case of the Wire and Arc Additive Manufacturing (WAAM) process, used for large‐scale structures, the as‐built roughness is estimated to several hundreds of micrometers. For complex geometries, a complete machining of the surfaces is not necessarily possible. In this study, an experimental method is proposed, relying on thermoelastic stress analysis, to characterize the effect of as‐built WAAM surface roughness on high‐cycle fatigue properties. Using an infrared camera, multiple cracks can be detected and monitored over a large surface on rough WAAM samples under cyclic bending. The collected data constitutes valuable information for the identification of a fatigue model dedicated to as‐built WAAM structures.

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Section: Introductionmentioning

confidence: 91%

“…An arithmetic average roughness

R_{a}

under

50 normalμ

R_{a}

Section: Introductionmentioning

confidence: 99%

K_{t}

is determined and associated with the experimental fatigue lives.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Thermometric investigations for the characterization of fatigue crack initiation and propagation in Wire and Arc Additively Manufactured parts with as‐built surfaces

Bercelli

Doudard

Calloch

et al. 2022

Fatigue Fract Eng Mat Struct

View full text Add to dashboard Cite

show abstract

“…This includes a broad variety of complex mechanical testing, investigating different stages of fatigue damage, to control nucleated cracks and prevent the final fatigue failure [12]. Having said that, fatigue assessment becomes crucial for AM built components that consist of welding defects and tensile residual stresses-two major factors contributing to the fatigue failures [13]. Some industries, such as aerospace and automotive, have already introduced and are widely implementing AM processes.…”

Section: Introductionmentioning

confidence: 99%

Fatigue life assessment of wire arc additively manufactured ER100S-1 steel parts

et al. 2023

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The aim of this work was to examine uniaxial, torsion, and multi-axial fatigue characteristics of ER100S-1 low carbon steel specimens fabricated with wire arc additive manufacturing (WAAM) technique, a subcategory of directed energy deposition (DED). Two distinct specimen orientations were tested—vertical and horizontal, extracted perpendicular and parallel to the WAAM deposited layers, respectively. Fracture surfaces of the tested specimens were analysed under scanning electron microscope (SEM) to observe fracture mechanisms corresponding to different specimen orientations, different fatigue loading conditions, and to interpret the fatigue results obtained from the tests. Finally, the obtained stress–life results were compared with the fatigue data available in the literature for a series of wrought and WAAM-built structural steel specimens. Moreover, the S–N curves obtained in this study were evaluated against the fatigue design curve recommended for offshore marine welded structures in DNV standard. Test results have shown advantageous characteristics of WAAM-built ER100S-1 specimens compared with behaviours of other structural steels and conservative prediction of its fatigue life by the design curve available in the DNV standard.

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“…Fatigue fracture assessment of DED-Arc manufactured parts, reported in literature, can be divided in two main groups, namely stress/strain based fatigue tests [2] and fatigue crack growth studies [3,4]. In respect to the surface quality, the research works mainly focus on post-machined [2,5] and as-built surface conditions [6,7]. Some researchers have investigated the influence of different printing parameters on fatigue fracture of as-built AM materials [8][9][10].…”

Section: Introductionmentioning

confidence: 99%

Influence of post-heat treatments on fatigue response of low-alloyed carbon-manganese steel material manufactured by Direct Energy Deposition-Arc technique

et al. 2021

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The main idea of this paper is improving fatigue response of a low-alloyed carbon-manganese steel material manufactured by Direct Energy Deposition-Arc technique using post-heat treatments. Four series of fatigue specimens are machined from a 3D printed wall. The machined samples are austenitized following a direct quenching and tempering processes at two different temperatures. All samples are subjected to rotating bending fatigue loading conditions. Next, microhardness, microstructures and fracture surfaces of the fatigue samples are analysed. Despite of very low carbon content, a full martensitic transformation was observed after the post-heat treatments which resulted in considerably higher fatigue lifetimes compared to non-treated ones. The quenched samples gave the best improvement when compared to as-printed and tempered samples.

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Fatigue analysis of wire arc additive manufactured (3D printed) components with unmilled surface

Cited by 54 publications

References 29 publications

Thermometric investigations for the characterization of fatigue crack initiation and propagation in Wire and Arc Additively Manufactured parts with as‐built surfaces

Thermometric investigations for the characterization of fatigue crack initiation and propagation in Wire and Arc Additively Manufactured parts with as‐built surfaces

Fatigue life assessment of wire arc additively manufactured ER100S-1 steel parts

Influence of post-heat treatments on fatigue response of low-alloyed carbon-manganese steel material manufactured by Direct Energy Deposition-Arc technique

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