The effect of manufacturing defects on the fatigue life of selective laser melted Ti-6Al-4V structures

Hu, Yuqing; Wu, Shengchuan; Zhang, J.; Bao, Hongyixi; Fu, Yanan; Kang, Guozheng

doi:10.1016/j.matdes.2020.108708

Cited by 267 publications

(76 citation statements)

References 39 publications

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“…Hybrid specimens, with their AM part manufactured via SLM were tested for microstructural variations, presence of defects, uniaxial tensile ductility and fracture toughness for several configurations. While defects were found in both the AM part of the specimen and its wrought counterpart, their characteristics were not different from those reported in the literature for other SLM Ti-6Al-4V specimens [43,46,47]. Moreover, the spatial variability of defects did not exhibit any correlation with the location of the AM-wrought interface.…”

Section: Discussioncontrasting

confidence: 46%

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Dolev

Osovski

Shirizly

2021

Additive Manufacturing

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The implementation of additive manufacturing techniques in the production of mission critical structural components is challenged by its low throughput and limited build envelope. In recent years, hybrid production methods are emerging to bridge between the build volume and high throughput of conventional production methods and the design freedom enabled by additive manufacturing. The repeatability of material properties and the quality of the interface between the additive manufactured and wrought material are crucial for the adoption of hybrid manufacturing techniques by the industry. Here, the tensile behavior and fracture toughness of a hybrid Ti-6Al-4V alloy are examined in detail. Ti-6Al-4V pre-forms were built onto a wrought Ti-6Al-4V start-plate and extracted via milling. Compact tension and uniaxial tension specimens extracted from the hybrid pre-forms demonstrated good fracture and properties with no preference for crack growth in neither the AM nor wrought materials. Microstructural characterization revealed a 40 mm transition layer into the wrought material which ends abruptly with no evidence of a gradually decaying heat-affected zone. The hybrid manufacturing approach studied here expands the current limitations of large-scale critical components with fine features and allow such structures to be produced with a higher throughput.

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Section: Discussioncontrasting

confidence: 46%

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Dolev

Osovski

Shirizly

2021

Additive Manufacturing

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Section: Discussioncontrasting

confidence: 52%

Ti6Al4V Hybrid Structure Mechanical Properties – Wrought and Additive Manufactured Powder-Bed Material

Dolev¹,

Osovski²,

Shirizly³

2020

Preprint

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The implementation of additive manufacturing techniques in the production of mission critical structural components is challenged by its low throughput and limited build envelope. In recent years, hybrid production methods are emerging to bridge between the build volume and high throughput of conventional production methods and the design freedom enabled by additive manufacturing. The repeatability of material properties and the quality of the interface between the additive manufactured and wrought material are crucial for the adoption of hybrid manufacturing techniques by the industry. Here, the tensile behavior and fracture toughness of a hybrid Ti6Al4V alloy are examined in detail. Ti6Al4V pre-forms were built onto a wrought Ti6Al4V start-plate and extracted via milling. Compact tension and uniaxial tension specimens, extracted from the hybrid pre-forms demonstrated good fracture and properties with no preference for crack growth in neither the AM or wrought materials. Microstructural characterization revealed a sharp interface between the two materials with no evidence of a heat-affected zone. The hybrid manufacturing approach studied here expands the current limitations of large scale critical components with fine features and allow such structures to be produced with a higher thruput.

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“…Indeed, the tensile strength of AM parts is generally close to that of parts produced through traditional processes, despite the different manufacturing processes and the different microstructures. Moreover, the scatter associated with the quasi-static tensile properties is generally limited, [7][8][9] thus ensuring a safe use of AM components when subjected to static stress.…”

Section: Introductionmentioning

confidence: 99%

“…For these reasons, the fatigue response of AM parts is typically worse than that of traditionally built parts, which are generally free of large defects with sizes comparable to those of AM parts. [9][10][11][12][13][14] The aim of the research is therefore to optimize the process parameters or the post-treatments in order to limit the formation of defects 15,16 or to define damage tolerance design approaches capable to ensure the structural integrity of AM parts, since the design procedure commonly adopted cannot be conservative and effective. 13 In order to properly compare the results of tests on AM parts and assess the influence of process parameters and post-treatments, the experimental data should be properly analyzed.…”

Section: Introductionmentioning

confidence: 99%

Fatigue failures from defects in additive manufactured components: A statistical methodology for the analysis of the experimental results

Tridello

Niutta

Berto

et al. 2021

Fatigue Fract Eng Mat Struct

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The fatigue response of additive manufactured (AMed) components is generally controlled by the defect population, and the models for assessing the fatigue response of AMed parts have to take into account the distribution of defect size and the intrinsic scatter associated to the fatigue response. In the present paper, a statistical methodology for analyzing the results of tests on AMed specimens failed due to cracks originating from defects is proposed. The procedure involves the estimation of the distribution of the fatigue life, which is considered dependent on the applied stress amplitude and on the defect size. Thereafter, all the experimental failures are shifted at a reference number of cycles to failure or stress amplitude, making it possible to compare data obtained at different stress levels or number of cycles to failure. The proposed method has been successfully validated on literature dataset, proving its effectiveness and general validity.

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The effect of manufacturing defects on the fatigue life of selective laser melted Ti-6Al-4V structures

Cited by 267 publications

References 39 publications

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Ti6Al4V Hybrid Structure Mechanical Properties – Wrought and Additive Manufactured Powder-Bed Material

Fatigue failures from defects in additive manufactured components: A statistical methodology for the analysis of the experimental results

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