Interior initiation and early growth of very high cycle fatigue crack in an additively manufactured Ti-alloy

Chi, Weiqian; Li, Gen; Wang, Wenjing; Sun, Chengqi

doi:10.1016/j.ijfatigue.2022.106862

Cited by 28 publications

(9 citation statements)

References 50 publications

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“…In addition, the selection of stress amplitude and load period of variable amplitude fatigue test is also based on the relevant literature (Chi et al, 2022).…”

Section: Materials and Experimental Proceduresmentioning

confidence: 99%

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Ultra-high cycle fatigue and ultra-slow crack growth behavior of additively manufactured AlSi7Mg alloy

Zhao,

Li,

et al. 2024

IJSI

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PurposeThe purpose of this paper is to determine the ultra-high cycle fatigue behavior and ultra-slow crack propagation behavior of selective laser melting (SLM) AlSi7Mg alloy under as-built conditions.Design/methodology/approachConstant amplitude and two-step variable amplitude fatigue tests were carried out using ultrasonic fatigue equipment. The fracture surface of the failure specimen was quantitatively analyzed by scanning electron microscope (SEM).FindingsThe results show that the competition of surface and interior crack initiation modes leads to a duplex S–N curve. Both manufacturing defects (such as the lack of fusion) and inclusions can act as initially fatal fatigue microcracks, and the fatigue sensitivity level decreases with the location, size and type of the maximum defects.Originality/valueThe research results play a certain role in understanding the ultra-high cycle fatigue behavior of additive manufacturing aluminum alloys. It can provide reference for improving the process parameters of SLM technology.

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“…In addition, the selection of stress amplitude and load period of variable amplitude fatigue test is also based on the relevant literature (Chi et al, 2022).…”

Section: Materials and Experimental Proceduresmentioning

confidence: 99%

“…Most of the AM parts have gas pore and lack of fusion defects (Yang et al, 2020;Liu et al, 2020;Chi et al, 2022), which have an important influence on the fatigue performance of the material. Gas pore and lack of fusion defects can also be seen in this study, as shown in Figures 2 and 3.…”

Section: Microstructure and Defect Characteristicsmentioning

confidence: 99%

Ultra-high cycle fatigue and ultra-slow crack growth behavior of additively manufactured AlSi7Mg alloy

Zhao,

Li,

et al. 2024

IJSI

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“…For the fatigue failure caused by interior inclusions, the matrix structure diagram around the inclusion cluster before cyclic loading is drawn, Figure 8b. Secondly, under the combined action of cyclic normal stress, surface residual stress and the mismatch of elastic modulus between inclusions and matrix, grain refinement occurs around the inclusion cluster due to local stress concentration [41]. Subsequently, under the cyclic loading of variable amplitude loading, the grain begins to slip and dislocation accumulation around the inclusion cluster, which makes the grain rearrange to the new grain boundary and further forms a fine grain layer composed of sub grains.…”

Section: Analysis Of Failure Mechanism For Interior Fatigue Failurementioning

confidence: 99%

Interior micro‐defect induced cracking mechanism and life prediction of carburized Cr−Ni steel based on double nonlinear damage under variable amplitude loading

Deng

Kang

Guo

et al. 2023

Materialwissenschaft Werkst

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The constant/variable amplitude loading fatigue test with interior inclusionfine granular area-fisheye induced failure under R = 0 were carried out on carburized CrÀ Ni steel. The results showed that the fatigue life under variable amplitude loading is longer than that under constant amplitude loading in very-high-cycle fatigue regime under same maximum stress level, and the surface morphology of fine granular area under variable amplitude loading is coarser than that under constant amplitude loading under same order of magnitude of fatigue life. Simultaneously, it can be determined that the formation micro-mechanism of fine granular area is caused by the continuous deboning due to stress concentration around interior micro-defects. Furthermore, the life prediction model based on double nonlinear fatigue damage, which considers the coupling effect of local equivalent stress (surface residual stress and local stress concentration effect), loading sequence, failure mechanism and nonlinear characteristics of fatigue damage under constant/variable amplitude loading is established, and predicted life has good accuracy within the factor-of-three lines.

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“…Sun et al 10 identified that surface or internal microstructural defects dominate the failure of SLM Ti-6Al-4V in VHCF regime and observed fish-eye pattern (FiE) and fine granular area (FGA) features surrounding the crack source, with crack growth rates of about 10 À13 -10 À11 m/ cycle inside FGA. 11 Electron backscatter diffraction was adopted to observe the characteristics of the FGA. The FGA SIF amplitude ΔK FGA was calculated with the help of the above mentioned ffiffiffiffiffiffiffiffiffi area p parameter estimation model and found to correspond to the crack growth threshold of conventionally processed (CP) Ti-6Al-4V alloy in ultra-high vacuum environment.…”

Section: Effect Of Internal Defectsmentioning

confidence: 99%

“…Sun et al 10 identified that surface or internal microstructural defects dominate the failure of SLM Ti‐6Al‐4V in VHCF regime and observed fish‐eye pattern (FiE) and fine granular area (FGA) features surrounding the crack source, with crack growth rates of about 10 −13 –10 −11 m/cycle inside FGA 11 . Electron backscatter diffraction was adopted to observe the characteristics of the FGA.…”

Section: Fatigue Characteristics Of Am Metalsmentioning

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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Interior initiation and early growth of very high cycle fatigue crack in an additively manufactured Ti-alloy

Cited by 28 publications

References 50 publications

Ultra-high cycle fatigue and ultra-slow crack growth behavior of additively manufactured AlSi7Mg alloy

Ultra-high cycle fatigue and ultra-slow crack growth behavior of additively manufactured AlSi7Mg alloy

Interior micro‐defect induced cracking mechanism and life prediction of carburized Cr−Ni steel based on double nonlinear damage under variable amplitude loading

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

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