Predictive model to design for high cycle fatigue of stainless steels produced by metal additive manufacturing

Serjouei, Ahmad; Afazov, Shukri

doi:10.1016/j.heliyon.2022.e11473

Cited by 6 publications

(8 citation statements)

References 41 publications

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“…The information from the characterization (size, aspect ratio and surface roughness) is then used as an input into a fatigue model based on the endurance limit approach. 58 The pit size and aspect ratio were modeled using a notch theory by identifying the notch sensitivity of the material. The surface roughness generated from corrosion is also included in the fatigue model using a surface theory.…”

Section: Corrosion-based Fatigue Methodologymentioning

confidence: 99%

“…The corrosion characterization consists of identifying the pit size, pit shape (aspect ratio) and surface roughness at the pit. The information from the characterization (size, aspect ratio and surface roughness) is then used as an input into a fatigue model based on the endurance limit approach 58 . The pit size and aspect ratio were modeled using a notch theory by identifying the notch sensitivity of the material.…”

Section: Methodsmentioning

confidence: 99%

“…The surface factor, f s , depends on the UTS and the average surface roughness value, R a . 58 The validity range for f s varies with different materials, their surface finish, and the specific roughness measurements (R a ). Values for f s typically fall in a range between 0.5 and 1, with a value of 1 indicating that the surface roughness does not affect fatigue strength and values less than 1 indicating a reduction in fatigue strength due to the surface finish.…”

Section: Corrosion-based Fatigue Model With Incorporated Corrosion Fa...mentioning

confidence: 99%

“…A predictive model based on the endurance limit approach has been used to determine surface factors and defect factors in metal additive manufacturing. 58 Still, the research work did not include any consideration of corrosion or welding. Despite the conducted research in the literature, the relationship between corroded surface morphology and fatigue life can be improved, especially in welded parts used in offshore structures.…”

Section: Introductionmentioning

confidence: 99%

“…The primary obstacles stem from the difficulty in determining the pit size, position, form, location and how they interact with fatigue strength and loading cycles. A predictive model based on the endurance limit approach has been used to determine surface factors and defect factors in metal additive manufacturing 58 . Still, the research work did not include any consideration of corrosion or welding.…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

Corrosion surface morphology‐based methodology for fatigue assessment of offshore welded structures

Okenyi,

Afazov,

Mansfield

et al. 2023

Fatigue Fract Eng Mat Struct

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This work employed a novel corrosion‐based fatigue model to determine the fatigue life of offshore welded structures to enable the fatigue assessment of welds under corrosive conditions. In addition to the material's ultimate strength, endurance limit, and stress ratio (mean stress effect), the model includes a corrosion factor concept to account for the impact of corrosion pits on the fatigue performance of welded S355 steel, which is the novel contribution in this paper. X‐ray computed tomography scans of corroded S355 specimens in a salt spray chamber were characterized. Surface texture characterization was employed to obtain surface roughness, size, and aspect ratio of corrosion pits. The corrosion factor was determined based on notch and surface fatigue theories using the characterized pit size, aspect ratio, and surface roughness. Fatigue S‐N curves were then predicted for critical pits and compared against the fatigue code DNVGL‐RP‐C203 and experimental data from the literature. The novel approach combining corrosion characterization method with corrosion‐based fatigue model for the prediction of fatigue S‐N curves provided a minor deviation of only 2.8% between predicted and measured data. This approach can potentially be integrated into predictive frameworks for the remaining life assessment of offshore structures.

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Section: Corrosion-based Fatigue Methodologymentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Corrosion-based Fatigue Model With Incorporated Corrosion Fa...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Corrosion surface morphology‐based methodology for fatigue assessment of offshore welded structures

Okenyi,

Afazov,

Mansfield

et al. 2023

Fatigue Fract Eng Mat Struct

Self Cite

View full text Add to dashboard Cite

show abstract

Model-Based Material and Process Definitions for Additive Manufactured Component Design and Qualification

Furrer,

Ghosh,

Rollett

et al. 2024

Integr Mater Manuf Innov

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Defect-based fatigue model for additive manufacturing

et al. 2022

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A novel defect-based fatigue model for the prediction of S–N (stress versus number of cycles) data points and curves is proposed in this paper. The model is capable of predicting the material fatigue performance based on defect size and location from the surface. A defect factor was introduced and obtained based on notch theory, which considers the notch sensitivity of the material as well as the stress concentration obtained using the finite element method. A newly developed equation was applied to represent the relationship between the defect factor, defect size and defect location from the surface. AlSi10Mg samples were manufactured using laser powder bed fusion, and then machined. The samples were tested under rotational bending cyclic loading until failure. The failed samples were analysed using scanning electron microscopy and it was found that cracks initiated from defects located at the surface. The measured defect size and location were used to predict the number of cycles for an applied stress using the proposed defect-based fatigue model. This model was validated by comparing the predicted and experimentally obtained S–N data. The proposed model has the potential to be applied to component-level fatigue assessment and integrated into industrial quality assurance workflows. For instance, defects can be measured for each produced industrial component and directly assessed against fatigue performance using the developed defect-based fatigue model. This could enable the rapid approval and certification of future additively manufactured industrial components, which can unleash the commercial potential of additive manufacturing for light-weight multi-functional component designs.

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Predictive model to design for high cycle fatigue of stainless steels produced by metal additive manufacturing

Cited by 6 publications

References 41 publications

Corrosion surface morphology‐based methodology for fatigue assessment of offshore welded structures

Corrosion surface morphology‐based methodology for fatigue assessment of offshore welded structures

Model-Based Material and Process Definitions for Additive Manufactured Component Design and Qualification

Defect-based fatigue model for additive manufacturing

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