Overview on Microstructure- and Defect-Sensitive Fatigue Modeling of Additively Manufactured Materials

Torries, Brian; Imandoust, Aidin; Beretta, S.; Shao, Shuai; Shamsaei, Nima

doi:10.1007/s11837-018-2987-9

Cited by 54 publications

(16 citation statements)

References 101 publications

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“…The microstructure-sensitive fatigue (MSF) model, proposed by McDowell et al [20] for automotive cast aluminum alloy and subsequently modified to account for mechanisms in other materials [21,22] and materials processing methods [23,24] including fusion-based AM [25,26], was used to correlate the experimental fatigue results and to aid in elucidating the effect of microstructure evolution on fatigue mechanisms due to the AFS-D process. The model aims to take into account various microstructural features, such as particle size, shape, nearest neighbor distance, grain size, crystallographic texture, etc., when modeling the fatigue behavior of a material.…”

Section: Microstructure-sensitive Fatigue Modelmentioning

confidence: 99%

Effect of Thermomechanical Processing on Fatigue Behavior in Solid-State Additive Manufacturing of Al-Mg-Si Alloy

Rutherford

Avery

Phillips

et al. 2020

Metals

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This work presents, for the first time, an in-depth investigation of the structure–property–fatigue relationships of an Al-Mg-Si alloy (AA6061) processed via additive friction stir-deposition (AFS-D). As industry focus continues to shift for more efficient and lightweight structures, quantitative studies on the cyclic performance of additively manufactured materials are needed. In this study, the AFS-D processed AA6061-T6 was machined into specimens in two orthogonal orientations and subjected to monotonic and strain-controlled fatigue testing. The microstructural features of as-deposited AA6061 exhibited evidence of dynamic recrystallization and grain refinement. In addition, significant reduction in the intermetallic particles was observed after AFS-D processing. The fatigue results demonstrate that the as-deposited material, particularly the longitudinal direction, exhibited similar fatigue performance to wrought AA6061-T6 in both low-cycle and high-cycle fatigue regimes, which is a promising result for additively manufactured material in the as-deposited condition. By contrast, the as-deposited build direction orientation possessed slightly lower fatigue resistance than the wrought feedstock material. The AFS-D material was observed to exhibit different damage mechanisms from porosity-based damage mechanisms observed in fusion-based additively manufactured materials. Lastly, a microstructure-sensitive fatigue model was employed to capture the fatigue effects of the AFS-D processing on the AA6061.

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Section: Microstructure-sensitive Fatigue Modelmentioning

confidence: 99%

Effect of Thermomechanical Processing on Fatigue Behavior in Solid-State Additive Manufacturing of Al-Mg-Si Alloy

Rutherford

Avery

Phillips

et al. 2020

Metals

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“…Additive manufacturing techniques to produce net shape parts for use in a variety of aerospace and biomedical applications have progressed significantly in the recent years. While most applications for additive manufactured (AM) parts involve post processing techniques to minimize the effects of porosity and surface roughness, the ability to produce net shaped parts to immediately put into service is a prominent goal of additive manufacturing . It is well established that the fatigue behavior of AM parts is highly sensitive to their surface roughness/defects, and significant efforts have been given to characterize the mechanical behavior of AM parts in the as‐built surface condition …”

Section: Introductionmentioning

confidence: 99%

Fatigue life estimation of additive manufactured parts in the as‐built surface condition

Pegues

Shamsaei

Roach

et al. 2019

Mat Design & Process Comms

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In this study, a simple approach for estimating the effect of surface roughness on the fatigue strength of additive manufactured Ti‐6Al‐4V is investigated. Surface roughness parameters are used to estimate the elastic stress concentration factor and the resulting fatigue stress concentration factor. The estimated fatigue strengths are then compared with experimentally obtained fatigue strengths for specimen batches with varying surface conditions. Results show that the estimated fatigue strengths are comparable with the experimental fatigue strengths, and the predicted stress‐life curves fit the experimental data reasonably well.

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“…The general form of the Hartman-Schijve variant of the NASGRO equation that was used in this paper is as given in [22]:…”

Section: Methodsmentioning

confidence: 99%

“…In this context, it should be noted that it has long been known that the residual stresses resulting from the manufacturing processes can significantly influence crack growth in laser shock peened parts, AM parts, and FSW parts [18][19][20][21][22][23]. It is now known [24][25][26][27] that, for welded structures, provided that allowance is made for the effect that the residual stress intensity factor (K res ) has upon the true range of the stress intensity factor (∆K true ) and on the true value of the maximum stress intensity factor (K true,max ), then crack growth can often be reasonably accurately computed.…”

Section: Introductionmentioning

confidence: 99%

Review of Requirements for the Durability and Damage Tolerance Certification of Additively Manufactured Aircraft Structural Parts and AM Repairs

et al. 2020

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The USAF requirements for the durability and damage tolerance certification for additively manufactured (AM) aircraft structural parts, which are detailed in Structures Bulletin EZ-19-01, raise a number of new and, as yet, unanswered questions. The present paper attempts to address three questions: How to perform a fracture mechanics-based analysis of crack growth in an AM part so as to account for the residual stresses, how to perform a fracture mechanics-based durability analysis of a cold spray repair so as to account for both the induced residual stresses and the presence of multiple co-located cracks, and how to perform a fracture mechanics-based durability analysis of an AM part so as to account for the presence of multiple collocated surface braking cracks. In this context, the present paper reveals the potential of the Hartman–Schijve variant of the NASGRO crack growth equation to accurately predict the growth of each of the individual (collocated) cracks that arose in a cold spray-repaired specimen and in a specimen from a crack that nucleated and grew from a rough surface.

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Overview on Microstructure- and Defect-Sensitive Fatigue Modeling of Additively Manufactured Materials

Cited by 54 publications

References 101 publications

Effect of Thermomechanical Processing on Fatigue Behavior in Solid-State Additive Manufacturing of Al-Mg-Si Alloy

Effect of Thermomechanical Processing on Fatigue Behavior in Solid-State Additive Manufacturing of Al-Mg-Si Alloy

Fatigue life estimation of additive manufactured parts in the as‐built surface condition

Review of Requirements for the Durability and Damage Tolerance Certification of Additively Manufactured Aircraft Structural Parts and AM Repairs

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