Efficient experimental methods for rapid fatigue life estimation of additive manufactured elements
Source abstract
Abstract
Three techniques for the assessment of the fatigue response of AMed parts are compared: defect analysis and subsequent theoretical estimation of the fatigue strength with micro-CT, infrared thermography and ultrasonic fatigue testing. Experimental tests on AlSi10Mg specimens are carried out and proved that each investigated technique can be used for a rapid estimation of the fatigue response. The thermography technique and ultrasonic fatigue tests proved to be effective, evidencing the most critical defects. The fatigue response estimated starting from the defect analysis with micro-CT scans is mainly suggested for the inspection of large components.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Aluminum Alloy Microstructure Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (64)
Show source-provided references
1. Metal additive manufacturing in aerospace: A review10.1016/j.matdes.2021.110008 ↗
2. 3D printing of high-strength aluminium alloys10.1038/nature23894 ↗
3. A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties10.1016/j.pmatsci.2015.03.002 ↗
4. Comparative study of performance comparison of AlSi10Mg alloy prepared by selective laser melting and casting10.1016/j.jmst.2019.08.049 ↗
5. Heat treatment of aluminium alloys produced by laser powder bed fusion: A review
6. CEN European Committee for Standardization. Eurocode 3 - Design of steel structures - Part 1-9: Fatigue 2005.
7. CEN European Committee for Standardization. Eurocode 9 - Design of aluminium structures - Part 1-3: Structures susceptible to fatigue 2021.
8. Very high cycle fatigue - Is there a fatigue limit?10.1016/j.ijfatigue.2010.05.009 ↗
9. Selective laser melting of AlCu-TiB2 alloy using pulsed wave laser emission mode: processability, microstructure and mechanical properties
10. Multi-scale defects in powder-based additively manufactured metals and alloys10.1016/j.jmst.2022.02.015 ↗
11. Specific features and mechanisms of fatigue in the ultrahigh-cycle regime10.1016/j.ijfatigue.2005.05.018 ↗
12. Fatigue properties of AlSi10Mg obtained by additive manufacturing: Defect-based modelling and prediction of fatigue strength10.1016/j.engfracmech.2017.11.002 ↗
13. 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 ↗
14. Quality control of AlSi10Mg produced by SLM : Metallography versus CT scans for critical defect size assessment
15. Thermographic methodology for rapid determination of the fatigue limit of materials and mechanical components10.1016/S0142-1123(99)00088-2 ↗
16. Very high cycle fatigue measuring techniques10.1016/j.ijfatigue.2012.11.016 ↗
17. Low temperature annealing dedicated to AlSi10Mg selective laser melting products10.1016/j.jallcom.2016.12.019 ↗
18. Ad Hoc Heat Treatments for Selective Laser Melted AlSi10Mg Alloy Aimed at Stress-Relieving and Enhancing Mechanical Performances10.1007/s11837-019-03973-z ↗
19. On specimen design for size effect evaluation in ultrasonic gigacycle fatigue testing10.1111/ffe.12149 ↗
20. VHCF response of Gaussian specimens made of high-strength steels: comparison between unrefined and refined AISI H1310.1111/ffe.12610 ↗
21. Murakami · 2002
22. Effects of defects on mechanical properties in metal additive manufacturing: A review focusing on X-ray tomography insights10.1016/j.matdes.2019.108385 ↗
23. Estimating the intrinsic dissipation using the second harmonic of the temperature signal in tension-compression fatigue: Part I10.1111/ffe.13485 ↗
24. An energy method for rapid evaluation of high-cycle fatigue parameters based on intrinsic dissipation10.1016/j.ijfatigue.2015.04.016 ↗
25. Brémond P. New developments in Thermo Elastic Stress Analysis by Infrared Thermography. IV Conf. Panam. END, Buenos Aires: 2007.
26. Rapid estimation of fatigue limit for C45 steel by thermography and digital image correlation10.1177/0309324720975284 ↗
27. The use of a second harmonic correlation to detect damage in composite structures using thermoelastic stress measurements10.1046/j.1475-1305.2003.00056.x ↗
28. A review of thermographic techniques for damage investigation in composites
29. The heat energy dissipated in the material structural volume to correlate the fatigue crack growth rate in stainless steel specimens10.1016/j.ijfatigue.2018.07.037 ↗
30. Analysis of the fatigue strength of a stainless steel based on the energy dissipation10.1016/j.ijfatigue.2006.02.043 ↗
31. Dissipation in porous metal plasticity and ductile fracture10.1016/S0022-5096(01)00013-8 ↗
32. Fatigue limit evaluation of various martensitic stainless steels with new robust thermographic data analysis10.1016/j.ijfatigue.2014.12.010 ↗
33. Durability Reliability Demonstration Test Methods10.1016/j.proeng.2015.12.621 ↗
34. Nelson · 1990
35. The plotting of observations on probability paper10.1111/j.1467-9574.1953.tb00821.x ↗
36. The effect of defect population on the anisotropic fatigue resistance of AlSi10Mg alloy fabricated by laser powder bed fusion10.1016/j.ijfatigue.2021.106317 ↗
37. 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 ↗
38. An engineering estimation of fatigue thresholds from a microstructural size and Vickers hardness: application to wrought and additively manufactured metals10.1016/j.ijfatigue.2020.105796 ↗
39. A comparison of fatigue strength sensitivity to defects for materials manufactured by AM or traditional processes10.1016/j.ijfatigue.2016.06.020 ↗
40. Fatigue and fatigue crack propagation in AlSi7Mg cast alloys under in-service loading conditions10.1016/0142-1123(95)95895-N ↗
41. Effect of microstructure, residual stresses and building orientation on the fatigue response up to 109 cycles of an SLM AlSi10Mg alloy10.1016/j.ijfatigue.2020.105659 ↗
42. Quantification and characterisation of porosity in selectively laser melted Al-Si10-Mg using X-ray computed tomography10.1016/j.matchar.2015.12.001 ↗
43. Effect of heat treatment on the microstructure and anisotropy in mechanical properties of A357 alloy produced by selective laser melting10.1016/j.matdes.2018.05.026 ↗
44. Interpretation of the fatigue anisotropy of additively manufactured TA6V alloys via a fracture mechanics approach10.1016/j.engfracmech.2019.03.048 ↗
45. Modulating the damping capacity of SLMed AlSi10Mg trough stress-relieving thermal treatments10.1016/j.tafmec.2020.102537 ↗
46. On the fatigue strength enhancement of additive manufactured AlSi10Mg parts by mechanical and thermal post-processing10.1016/j.matdes.2018.02.055 ↗
47. Fatigue strength assessment of “as built” AlSi10Mg manufactured by SLM with different build orientations10.1016/j.ijfatigue.2020.105737 ↗
48. History of residual stresses during the production phases of AlSi10Mg parts processed by powder bed additive manufacturing technology10.1080/17452759.2017.1310439 ↗
49. Influence of shot peening on alsi10mg parts fabricated by additive manufacturing
50. The Influence of Porosity on Fatigue Crack Initiation in Additively Manufactured Titanium Components10.1038/s41598-017-06504-5 ↗
51. Fatigue of laser powder-bed fusion additive manufactured Ti-6Al-4V in presence of process-induced porosity defects10.1016/j.engfracmech.2021.108140 ↗
52. A new FE post-processor for probabilistic fatigue assessment in the presence of defects and its application to AM parts10.1016/j.ijfatigue.2019.04.008 ↗
53. Rapid characterization of the fatigue limit of additive-manufactured maraging steels using infrared measurements
54. Rapid evaluation of fatigue limit on thermographic data analysis10.1016/j.ijfatigue.2017.07.029 ↗
55. Fatigue limit evaluation of metals using an infrared thermographic technique10.1016/S0167-6636(97)00047-1 ↗
56. Fatigue damage in GFRP10.1108/17579861211281218 ↗
57. A new iteration method for the thermographic determination of fatigue limit in steels10.1016/j.ijfatigue.2003.12.009 ↗
58. Yang C, Zhu K, Liu Y, Cai Y, Liu W, Zhang K, et al. A comparative study of fatigue energy dissipation of additive manufactured and cast Alsi10Mg alloy. Metals (Basel) 2021;11. https://doi.org/10.3390/met11081274.10.3390/met11081274 ↗
59. De Finis R, Palumbo D, Serio LM, De Filippis LAC, Galietti U. Correlation between thermal behaviour of AA5754-H111 during fatigue loading and fatigue strength at fixed number of cycles. Materials (Basel) 2018;11. https://doi.org/10.3390/ma11050719.10.3390/ma11050719 ↗
60. Adopting lock-in infrared thermography technique for rapid determination of fatigue limit of aluminum alloy riveted component and affection to determined result caused by initial stress10.1016/j.ijfatigue.2011.09.005 ↗
61. In-situ Technique for Fatigue Life Prediction of Metals Based on Temperature Evolution10.1016/j.ijmecsci.2020.106113 ↗
62. Effect of delamination on the fatigue life of GFRP: A thermographic and numerical study10.1016/j.compstruct.2019.03.023 ↗
63. Fatigue and fatigue crack growth of aluminium alloys at very high numbers of cycles10.1016/S0142-1123(01)00167-0 ↗
64. Very high-cycle fatigue properties and microstructural damage mechanisms of selective laser melted AlSi10Mg alloy10.1016/j.ijfatigue.2019.02.040 ↗