Killer notches: The effect of as-built surface roughness on fatigue failure in AlSi10Mg produced by laser powder bed fusion

Plessis, Anton du; Beretta, Stefano

doi:10.1016/j.addma.2020.101424

Cited by 66 publications

(33 citation statements)

References 63 publications

(88 reference statements)

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“…The proposed methodology was validated considering smooth specimens; hence, only the effect of internal defects was taken into account, disregarding the effects of the ‘as‐built’ rough surface. In literature, there are several works dealing with the HCF of AM material considering the effect of the rough surface left by the manufacturing process 22,65–74 and modelling it in terms of propagation of the surface features. It is then expected that the present approach could allow the application of the same concepts to LCF conditions, even if the surface features are usually modelled as 2‐D cracks and not as semicircular defects.…”

Section: Model For Life Predictionmentioning

confidence: 99%

Anisotropic mechanical and fatigue behaviour of Inconel718 produced by SLM in LCF and high‐temperature conditions

Sausto

Marchese

Bassini

et al. 2020

Fatigue Fract Eng Mat Struct

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Additive manufacturing (AM) is one of the processes with the most potential for producing components used in internal combustion engines and features high efficiency due to the possibility of building very complex shapes. Several drawbacks of parts produced using AM are still unresolved, like poor surface quality, the presence of internal defects and anisotropic mechanical behaviour, which all contribute to decreasing the fatigue strength compared with the material produced using conventional processes. The effect of building direction on both the macroscopic mechanical behaviour and the crack propagation mechanism of Ni-base superalloy Inconel718 produced using AM was investigated under the combined effect of low cycle fatigue (LCF) and high temperature. The different crack growth mechanisms investigated using compact tension (CT) specimens, tested at high temperature, showed a significant difference between the two building directions. The LCF fatigue experiments also showed a significant difference in the ε-N curves from the two directions together with a high level of scatter due to the dispersion of the defect size at the fracture origin. The dimensions of the defects (as measured using the ffiffiffiffiffiffiffiffiffi area p parameter) were analysed by means of extreme value statistics and showed a significant difference between the two orientations investigated. The aim of this work is to propose a simplified approach (based on ΔJ eff concepts) to estimate the fatigue life of a component produced using AM that takes into account the material variability due to the combined effect of mechanical anisotropic behaviour and the presence of defects at high-temperature conditions.

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Section: Model For Life Predictionmentioning

confidence: 99%

Anisotropic mechanical and fatigue behaviour of Inconel718 produced by SLM in LCF and high‐temperature conditions

Sausto

Marchese

Bassini

et al. 2020

Fatigue Fract Eng Mat Struct

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“…As-built components with an outer surface with relatively high surface roughness influence the fatigue life of loaded components under, compressive, tensional and bending forces (Balachandramurthi et al, 2018;Bayati et al, 2020;Becker et al, 2020). Similar conclusions are drawn regardless of metal alloy regarding a negative relationship between an increase in surface roughness and lower fatigue performance, particularly in the as-built state (Harada et al, 2020;du Plessis and Beretta, 2020;Sprengel et al, 2019). The lower fatigue strength performance can be attributed to the notch effect and stress concentrations caused by the rough surface defects (Nicoletto et al, 2020;du Plessis and Beretta, 2020).…”

Section: Iced21mentioning

confidence: 58%

Surface Roughness Considerations in Design for Additive Manufacturing - A Literature Review

2021

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One often-cited benefit of using metal additive manufacturing (AM) is the possibility to design and produce complex geometries that suit the required function and performance of end-use parts. In this context, laser powder bed fusion (LPBF) is one suitable AM process. Due to accessibility issues and cost-reduction potentials, such ‘complex’ LPBF parts should utilise net-shape manufacturing with minimal use of post-process machining. The inherent surface roughness of LPBF could, however, impede part performance, especially from a structural perspective and in particular regarding fatigue. Engineers must therefore understand the influence of surface roughness on part performance and how to consider it during design. This paper presents a systematic literature review of research related to LPBF surface roughness. In general, research focuses on the relationship between surface roughness and LPBF build parameters, material properties, or post-processing. Research on design support on how to consider surface roughness during design for AM is however scarce. Future research on such supports is therefore important given the effects of surface roughness highlighted in other research fields.

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“…Since, zinc plating is an electrolytic proses, surface roughness is higher compared to zinc flake coating. As discussed in the literature [14][15][16][17] depending on the conditions, surface roughness can act as a stress concentrator and lead to premature crack initiation leading fractures due to fatigue. Therefore, fatigue performance was higher for zinc flake coating having better surface finish compared to Zn-Cr+3 plating.…”

Section: Resultsmentioning

confidence: 99%

Corrosion Effects on Fatigue Behavior of Zn-Cr+3 and Zn Flake Coated M8 DIN 933 Bolts

Yurtdaş¹,

İnce²,

Tanrıkulu³

et al. 2021

Sakarya University Journal of Science

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In this study, fatigue behavior of Zn-Cr+3 and zinc flake coated bolts was investigated experimentally by considering corrosion effects. Fatigue tests were conducted on M8x50x1.25 8.8 DIN 933 bolts at normal and corroded conditions at force amplitudes between 2.35 and 5.36 kN at test frequency of 75 Hz. A part of bolts was subjected to salt atmosphere for corrosion. According to the Wöhler curves obtained from fatigue tests before corrosion, zinc flake coated bolts showed 1.55 times higher fatigue life compared to Zn-Cr+3. After corrosion, fatigue tests showed that the fatigue life difference increased to 2.10 times for the zinc flake coating. Moreover, corrosion was found to be ineffective on crack initiation region. For both coatings and corrosion conditions, fatigue cracks were seen to initiate from the thread roots.

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Killer notches: The effect of as-built surface roughness on fatigue failure in AlSi10Mg produced by laser powder bed fusion

Cited by 66 publications

References 63 publications

Anisotropic mechanical and fatigue behaviour of Inconel718 produced by SLM in LCF and high‐temperature conditions

Anisotropic mechanical and fatigue behaviour of Inconel718 produced by SLM in LCF and high‐temperature conditions

Surface Roughness Considerations in Design for Additive Manufacturing - A Literature Review

Corrosion Effects on Fatigue Behavior of Zn-Cr+3 and Zn Flake Coated M8 DIN 933 Bolts

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