Fatigue testing and end of life investigation of a topology optimized connecting rod fabricated via selective laser melting
Source abstract
Abstract
A first assessment of product durability of an SLM Ti6Al4V conrod with a lightweighted structure was developed. Full-scale fatigue testing and finite element analyses of testing conditions were performed to determine stress cycles in critical regions. End of life (EOL) and metallurgical analysis completed the study. A fatigue diagram covering the finite life and estimating the infinite life load levels, difficult to estimate a priori, was obtained; this is the first relevant result toward fatigue assessment of AM components. Fatigue life for the SLM conrod was lower than the conventional one, however, EOL analysis pointed out potential future improvements.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Titanium Alloys Microstructure and Properties · Additive Manufacturing and 3D Printing Technologies
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (39)
Show source-provided references
1. Additive manufacturing - qualification and certification process for materials and components, accessed September 2020, https://rules.dnvgl.com/docs/pdf/DNVGL/CG/2017-11/DNVGL-CG-0197.pdf.
2. The potential contribution of light-weighting to reduce transport energy consumption
3. Materials and technologies for lightweighting of structural parts for automotive applications: a review10.4271/05-14-01-0007 ↗
4. Lightweight of a cross beam for commercial vehicles: development, testing and validation10.1016/j.matdes.2018.04.021 ↗
5. Application of laser metal deposition for a new model of assembled camshaft10.1007/s11665-019-04504-2 ↗
6. The potential for mass reduction of passenger cars and light commercial vehicles in relation to future CO2 regulatory requirements: Appendices; https://ec.europa.eu/clima/sites/clima/files/transport/vehicles/docs/ldv_downweighting_co2_appendices_en.pdf.
7. An impact of engine downsizing on change of engine weight
8. A textbook of machine design
9. Microstructures and mechanical properties of titanium alloy connecting rod made by powder forging process10.1016/j.matdes.2011.07.034 ↗
10. Titanium in the family automobile: the cost challenge10.1007/s11837-004-0144-0 ↗
11. Titanium in automotive production10.1002/adem.200310094 ↗
12. Numerical, mechanical, and metallurgical investigation of an innovative near net shape titanium selective laser melting engine component and comparison with the conventional forged one10.1002/adem.202100036 ↗
13. Development of heat treatments for Selective Laser Melting Ti6Al4V alloy: effect on microstructure, mechanical properties and corrosion resistance10.1002/adem.202000359 ↗
14. Afzal · A Comparative Study of Fatigue Behavior and Life Predictions of Forged Steel and PM Connecting Rods · 2004
15. Qualification of AM parts: extreme value statistics applied to tomographic measurements10.1016/j.matdes.2017.05.091 ↗
16. Low- and high-cycle fatigue resistance of Ti-6Al-4V ELI additively manufactured via selective laser melting: mean stress and defect sensitivity10.1016/j.ijfatigue.2017.10.021 ↗
17. Fatigue life of additively manufactured Ti–6Al–4V in the very high cycle fatigue regime10.1016/j.ijfatigue.2016.05.018 ↗
18. Fatigue characterization of Titanium Ti-6Al-4V samples produced by additive manufacturing10.1016/j.prostr.2016.06.395 ↗
19. 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 ↗
20. High Cycle Fatigue (HCF) Performance of Ti-6Al-4V alloy processed by selective laser melting10.4028/www.scientific.net/AMR.816-817.134 ↗
21. H. Soyama, F.Takeo, Effect of various peening methods on the fatigue properties of Titanium alloy Ti6Al4V manufactured by direct metal laser sintering and electron beam melting. Materials (Basel) 2020;13. 10.3390/ma13102216.10.3390/ma13102216 ↗
22. Improved fatigue strength of additively manufactured Ti6Al4V by surface post processing10.1016/j.ijfatigue.2020.105497 ↗
23. Effect of surface treatment on the fatigue strength of additive manufactured Ti6Al4V alloy10.3221/IGF-ESIS.53.26 ↗
24. Effects of build orientation on fatigue behavior of Ti-6Al-4V as-built specimens produced by direct metal laser sintering10.1016/j.prostr.2020.02.032 ↗
25. Electron beam additive manufacturing of titanium components: properties and performance10.1115/1.4025773 ↗
26. Fatigue performance evaluation of selective laser melted Ti–6Al–4V10.1016/j.msea.2014.01.041 ↗
27. An experimental and simulation study on build thickness dependent microstructure for electron beam melted Ti-6Al-4V10.1016/j.jallcom.2015.05.178 ↗
28. X. Tan, Y. Kok, W.Q. Toh, Y.J. Tan, M. Descoins, D. Mangelinck, S.B. Tor, K.F. Leong, C.K. Chua Revealing martensitic transformation and α/β interface evolution in electron beam melting three-dimensional-printed Ti-6Al-4V, Sci. Rep., 6 (2016), pp. 1-10. 10.1038/srep26039.10.1038/srep26039 ↗
29. Effect of build thickness and geometry on quasi-static and fatigue behavior of Ti-6Al-4V produced by electron beam melting
30. Fatigue assessment of Ti–6Al–4V circular notched specimens produced by selective laser melting10.3390/met7080291 ↗
31. Directed energy deposition versus wrought Ti-6Al-4V: a comparison of microstructure, fatigue behavior, and notch sensitivity10.1002/adem.201900220 ↗
32. Fatigue strength of blunt V-notched specimens produced by selective laser melting of Ti-6Al-4V10.1016/j.tafmec.2017.06.021 ↗
33. Small fatigue crack growth behavior of Ti-6Al-4V produced via selective laser melting: in situ characterization of a 3D crack tip interactions with defects10.1016/j.ijfatigue.2020.105638 ↗
34. Numerical prediction of the fatigue crack growth rate in SLM Ti-6Al-4V based on crack tip plastic strain10.3390/met10091133 ↗
35. Additive manufacturing of fatigue resistant materials: challenges and opportunities10.1016/j.ijfatigue.2017.01.001 ↗
36. Critical assessment of the fatigue performance of additively manufactured Ti–6Al–4V and perspective for future research10.1016/j.ijfatigue.2015.12.003 ↗
37. Chern · Int J Fatigue · 2019 · 119 · 17310.1016/j.ijfatigue.2018.09.022 ↗
38. Fatigue behaviour of additive manufactured materials: An overview of some recent experimental studies on Ti-6Al-4V considering various processing and loading direction effects10.1111/ffe.13000 ↗
39. The role of microstructure and local crystallographic orientation near porosity defects on the high cycle fatigue life of an additive manufactured Ti-6Al-4V10.1016/j.matchar.2020.110576 ↗