A fatigue life model accounting for the combined effect of surface roughness and microstructure: Application to SLM fabricated Hastelloy-X
Source abstract
Abstract
This study introduces a microstructure-sensitive fatigue life prediction framework based on CP-FFT which includes the effect of surface roughness. The model is applied to flat Hastelloy-X specimens fabricated using Selective Laser Melting. The surface roughness measured is incorporated introducing a free surface with sinusoidal profile. The framework can accurately predict the fatigue life reduction of rough flat specimens using the fatigue parameters of polished bulk specimens and introducing the actual microstructure and roughness. A parametric study shows a monotonic reduction of life with the roughness amplitude but a minor effect of the surface waviness.
Source: openalex_inverted_index · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Welding Techniques and Residual Stresses · Fatigue and fracture mechanics
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (58)
Show source-provided references
1. Fatigue crack growth in additively manufactured Hastelloy X - Influences of crack orientation and post-fabrication treatments
2. Stoffregen · 2014 · 635
3. Gas flow effects on selective laser melting (SLM) manufacturing performance10.1016/j.jmatprotec.2011.09.020 ↗
4. On the measurement of relative powder-bed compaction density in powder-bed additive manufacturing processes10.1016/j.matdes.2018.06.030 ↗
5. Top surface and side roughness of Inconel 625 parts processed using selective laser melting10.1108/13552540910943397 ↗
6. Fatigue characterization and modeling of additively manufactured Hastelloy-X superalloy10.1007/s11665-022-06595-w ↗
7. Analysis and optimisation of vertical surface roughness in micro selective laser melting10.1088/2051-672X/3/3/034007 ↗
8. The microstructure and mechanical properties of deposited-IN718 by selective laser melting10.1016/j.jallcom.2011.10.107 ↗
9. Waviness affects friction and abrasive wear10.1007/s11249-023-01736-1 ↗
10. Polycrystal plasticity simulations of fretting fatigue10.1016/S0142-1123(01)00150-5 ↗
11. Prediction of non propagating cracks10.1016/0013-7944(79)90081-X ↗
12. Prediction of fatigue regimes in notched components10.1016/0020-7403(78)90082-6 ↗
13. Effects of hardness and crack geometries on delta k sub th of small cracks emanating from small defects
14. A mechanistic approach to the Kitagawa–Takahashi diagram using a multiaxial probabilistic framework10.1016/j.engfracmech.2013.06.001 ↗
15. Simulation of the Kitagawa–Takahashi diagram using a probabilistic approach for cast Al-Si alloys under different multiaxial loads10.1016/j.ijfatigue.2016.08.014 ↗
16. Surface roughness visualisation for rapid prototyping models10.1016/S0010-4485(01)00201-9 ↗
17. Geometric roughness analysis in solid free-form manufacturing processes10.1016/S0924-0136(01)00897-4 ↗
18. Fatigue life prediction of machined components using finite element analysis of surface topography10.1016/j.ijfatigue.2005.07.031 ↗
19. Surface roughness characterization for fatigue life predictions using finite element analysis10.1016/j.ijfatigue.2008.05.020 ↗
20. Fatigue life prediction of additively manufactured material: Effects of surface roughness, defect size, and shape10.1111/ffe.12799 ↗
21. Numerical modelling of surface roughness effect on the fatigue behavior of Ti-6Al-4V obtained by additive manufacturing10.1016/j.ijfatigue.2019.02.014 ↗
22. Numerical study of normal contact stiffness: Non-Gaussian roughness and elastic–plastic behavior10.1177/1350650119893520 ↗
23. Surface roughness influence in micromechanical fatigue lifetime prediction with crystal plasticity models for steel10.1016/j.ijfatigue.2022.106792 ↗
24. Microstructure sensitive fatigue life prediction model for SLM fabricated Hastelloy-X10.1016/j.ijfatigue.2022.107372 ↗
25. Effect of printing direction and thickness on the mechanical behavior of SLM fabricated Hastelloy-X10.1016/j.ijplas.2022.103250 ↗
26. Fatigue behavior of additive manufactured 316L stainless steel parts: Effects of layer orientation and surface roughness
27. Fatigue life estimation of additive manufactured parts in the as-built surface condition
28. A continuum damage mechanics finite element model for investigating effects of surface roughness on rolling contact fatigue10.1016/j.ijfatigue.2020.105986 ↗
29. An analysis of the influence of grain size on the strength of FCC polycrystals by means of computational homogenization10.1016/j.actamat.2018.01.024 ↗
30. Tribologically induced crystal rotation kinematics revealed by electron backscatter diffraction10.1016/j.actamat.2021.117566 ↗
31. Micromorphic crystal plasticity approach to damage regularization and size effects in martensitic steels10.1016/j.ijplas.2021.103187 ↗
32. Modelling cyclic deformation of Inconel 718 superalloy by means of crystal plasticity and computational homogenization10.1016/j.ijsolstr.2017.06.014 ↗
33. The relation between macroscopic and microscopic strain hardening in FCC polycrystals10.1016/0001-6160(84)90222-0 ↗
34. On the accuracy of spectral solvers for micromechanics based fatigue modeling10.1007/s00466-018-1598-1 ↗
35. FFT based approaches in micromechanics: fundamentals, methods and applications10.1088/1361-651X/ac34e1 ↗
36. An FFT-based Galerkin method for homogenization of periodic media10.1016/j.camwa.2014.05.014 ↗
37. Finite strain FFT-based non-linear solvers made simple10.1016/j.cma.2016.12.032 ↗
38. Fourier-based schemes with modified green operator for computing the electrical response of heterogeneous media with accurate local fields10.1002/nme.4641 ↗
39. An algorithm for stress and mixed control in Galerkin-based FFT homogenization10.1002/nme.6069 ↗
40. High– and low–cycle fatigue crack initiation using polycrystal plasticity10.1098/rspa.2003.1258 ↗
41. The role of elastic anisotropy, length scale and crystallographic slip in fatigue crack nucleation10.1016/j.jmps.2013.01.001 ↗
42. Microstructure-sensitive computational modeling of fatigue crack formation10.1016/j.ijfatigue.2010.01.003 ↗
43. Microstructure-based fatigue modeling of cast A356-T6 alloy10.1016/S0013-7944(02)00021-8 ↗
44. Micromechanical methodology for fatigue in cardiovascular stents10.1016/j.ijfatigue.2012.04.022 ↗
45. Experimental charactrisation for micromechanical modelling of CoCr stent fatigue10.1016/j.biomaterials.2013.09.087 ↗
46. Polycrystal orientation distribution effects on microslip in high cycle fatigue10.1016/S0142-1123(02)00057-9 ↗
47. Mesoscale modeling of microstructurally small fatigue cracks in metallic polycrystals10.1016/j.msea.2014.01.015 ↗
48. A stored energy criterion for fatigue crack nucleation in polycrystals10.1016/j.ijfatigue.2014.06.001 ↗
49. Micro-scale testing and micromechanical modelling for high cycle fatigue of CoCr stent material10.1016/j.jmbbm.2015.02.011 ↗
50. Fatigue crack nucleation: Mechanistic modelling across the length scales10.1016/j.cossms.2014.02.005 ↗
51. Crystal plasticity FE study of the effect of thermo-mechanical loading on fatigue crack nucleation in titanium alloys10.1111/ffe.12410 ↗
52. The physics of fatigue crack initiation10.1016/j.ijfatigue.2012.10.009 ↗
53. Micromechanical study of the loading path effect in high cycle fatigue10.1016/j.ijfatigue.2013.09.014 ↗
54. Assessing reliability of fatigue indicator parameters for small crack growth via a probabilistic framework10.1088/1361-651X/aa6c45 ↗
55. Microstructure-sensitive computational modeling of fatigue crack formation10.1016/j.ijfatigue.2010.01.003 ↗
56. Investigation of surface roughness post-processing of additively manufactured nickel-based superalloy Hastelloy X using electropolishing10.1016/j.surfcoat.2022.128529 ↗
57. Analysis of the effect of surface roughness on fatigue performance of powder bed fusion additive manufactured metals10.1016/j.tafmec.2020.102638 ↗
58. Fatigue performance evaluation of selective laser melted Ti–6Al–4V10.1016/j.msea.2014.01.041 ↗