A new approach to correlate the defect population with the fatigue life of selective laser melted Ti-6Al-4V alloy
Source abstract
Abstract
Microstructural features and defects arising from selective laser melting (SLM) determine the in-service performance of additively manufactured near-net-shape components. Here the grain type, shape, size and distribution were characterized using electron backscattered diffraction (EBSD). High-resolution synchrotron radiation X-ray computed tomography (CT) was used to quantify the population, morphology and dimensions of porosity and lack of fusion defects. For SLM Ti-6Al-4V alloy, the larger-sized defects in comparison with the α grains are more important for crack initiation, typically leading to poor fatigue resistance and a pronounced variation in fatigue life. The fatigue strength was then evaluated in terms of the defect population using a combination of the statistics of extremes and the Murakami model. Finally, an extended Kitagawa-Takahashi fatigue diagram was established within the framework of defect-tolerant design, which includes a classical safe-life region and the defect-determined lifetime in the finite life region
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Welding Techniques and Residual Stresses · Additive Manufacturing and 3D Printing Technologies
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (52)
Show source-provided references
1. Fatigue strength prediction for titanium alloy TiAl6V4 manufactured by selective laser melting10.1007/s11661-015-2864-x ↗
2. Improvement of fatigue resistance and ductility of TiAl6V4 processed by selective laser melting10.1016/j.jmatprotec.2015.01.025 ↗
3. Fatigue performance evaluation of selective laser melted Ti-6Al-4V10.1016/j.msea.2014.01.041 ↗
4. Additive manufacturing of fatigue resistant materials: Challenges and opportunities10.1016/j.ijfatigue.2017.01.001 ↗
5. Data-driven evaluation of fatigue performance of additive manufactured parts using miniature specimens10.1016/j.jmst.2018.12.011 ↗
6. Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice10.1016/j.pmatsci.2019.100590 ↗
7. The influence of porosity on fatigue crack initiation in additively manufactured Titanium components10.1038/s41598-017-06504-5 ↗
8. Murakami · 2002
9. Collaborative crack initiation mechanism of 25CrMo4 alloy steels subjected to foreign object damages10.1016/j.engfracmech.2019.106844 ↗
10. Qualification of AM parts: extreme value statistics applied to tomographic measurements10.1016/j.matdes.2017.05.091 ↗
11. Quantification of the interaction within defect populations on fatigue behavior in an aluminum alloy10.1016/j.actamat.2009.04.008 ↗
12. Effect of small defects on the fatigue strength of martensitic stainless steels10.1016/j.ijfatigue.2019.06.021 ↗
13. Influence of defects, surface roughness and HIP on the fatigue strength of Ti-6Al-4V manufactured by additive manufacturing10.1016/j.ijfatigue.2018.07.020 ↗
14. The influence of defects on high cycle fatigue of metallic materials10.1016/S0924-0136(03)00409-6 ↗
15. The Kitagawa-Takahashi fatigue diagram to hybrid welded AA7050 joints via synchrotron tomography10.1016/j.ijfatigue.2019.04.002 ↗
16. Building the Kitagawa-Takahashi diagram of flawed materials and components using an optimized V-notched cylindrical specimen
17. Fatigue strength and fracture mechanics-A general perspective10.1016/j.engfracmech.2017.04.030 ↗
18. Prediction of non-propagating cracks10.1016/0013-7944(79)90081-X ↗
19. Fatigue propagation threshold of short cracks under constant amplitude loading10.1016/S0142-1123(03)00065-3 ↗
20. A new post-processor for probabilistic fatigue assessment in the presence of defects and its application to AM parts10.1016/j.ijfatigue.2019.04.008 ↗
21. Modified NASGRO equation for physically short cracks10.1016/j.ijfatigue.2013.08.019 ↗
22. Residual stresses in laser direct metal deposited Waspaloy10.1016/j.msea.2010.12.010 ↗
23. On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: Fatigue resistance and crack growth performance10.1016/j.ijfatigue.2012.11.011 ↗
24. Defect induced fatigue behaviors of selective laser melted Ti-6Al-4V via synchrotron radiation X-ray tomography
25. Hu YN, Wu SC, Withers PJ, Zhang J, Bao HYX, Fu YN, et al. The defect-induced fatigue life of selective laser melted Ti-6Al-4V alloy via synchrotron X-ray tomography. Mater Des; 2020, minor revision.
26. In-situ investigation on fatigue behaviors of Ti-6Al-4V manufactured by selected laser melting10.1016/j.ijfatigue.2019.105424 ↗
27. Anisotropy of fatigue crack growth in wire arc additive manufactured Ti-6Al-4V10.1016/j.msea.2017.10.064 ↗
28. Microstructure and mechanical properties of Ti-6Al-4V by electron beam rapid manufacturing10.1016/S1875-5372(14)60083-7 ↗
29. Microstructures and mechanical properties of Ti6Al4V parts fabricated by selective laser melting and electron beam melting10.1007/s11665-013-0658-0 ↗
30. Heat treatment of Ti6Al4V produced by selective laser melting: microstructure and mechanical properties10.1016/j.jallcom.2012.07.022 ↗
31. Fatigue performance of selective laser melted Ti6Al4V components: state of the art
32. Interrupted fatigue testing with periodic tomography to monitor porosity defects in wire + arc additive manufactured Ti-6Al-4V
33. The effect of bi-modal and lamellar microstructures of Ti-6Al-4V on the behaviour of fatigue cracks emanating from edge-notches10.1111/j.1460-2695.2004.00825.x ↗
34. Effect of build geometry on the β-grain structure and texture in additive manufacture of Ti6Al4V by selective electron beam melting10.1016/j.matchar.2013.07.012 ↗
35. Critical assessment of the fatigue performance of additively manufactured Ti-6Al-4V and perspective for future research10.1016/j.ijfatigue.2015.12.003 ↗
36. In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing10.1038/s41467-018-03734-7 ↗
37. Roles of microstructure in fatigue crack initiation10.1016/j.ijfatigue.2009.10.005 ↗
38. Criticality of porosity defects on the fatigue performance of wire + arc additive manufactured titanium alloy10.1016/j.ijfatigue.2019.01.017 ↗
39. The imaging of failure in structural materials by synchrotron radiation X-ray microtomography10.1016/j.engfracmech.2017.07.027 ↗
40. Linking microstructure and processing defects to mechanical properties of selectively laser melted AlSi10Mg alloy10.1016/j.tafmec.2018.09.011 ↗
41. Murakami Y, Beretta S. Small defects and inhomogeneities in fatigue strength: experiments, models and statistical implications. Extremes, 2(2): 123–147.10.1023/A:1009976418553 ↗
42. Influence of casting defects on the fatigue behavior of cast aluminum AS7G06-T610.1016/j.ijfatigue.2014.01.011 ↗
43. Mean stress effects in stress-life fatigue and the Walker equation10.1111/j.1460-2695.2008.01322.x ↗
44. A comparison of fatigue strength sensitivity to defects for materials manufactured by AM or traditional processes10.1016/j.ijfatigue.2016.06.020 ↗
45. Quantitative dependence of oxide-induced crack closure on air humidity for railway axle steel10.1016/j.ijfatigue.2019.02.019 ↗
46. Fatigue crack closure: a review of the physical phenomena10.1111/ffe.12578 ↗
47. Fatigue crack growth thresholds-the influence of Young's modulus and fracture surface roughness10.1016/S0142-1123(98)00034-6 ↗
48. A probabilistic Kitagawa-Takahashi diagram for fatigue strength assessment of cast aluminium alloys10.1016/j.msea.2018.12.108 ↗
49. Krupp · 2007
50. Generation of stress vs. crack length plots for a ferritic steel weld metal based on Kitagawa-Takahashi approach10.1016/j.matlet.2004.10.032 ↗
51. Representing crack growth in additively manufactured Ti-6Al-4V10.1016/j.ijfatigue.2018.07.019 ↗
52. Probabilistic fatigue assessment for high-speed railway axles due to foreign object damages10.1016/j.ijfatigue.2018.08.011 ↗