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Fatigue in Materials Produced by Additive Manufacturing
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Fatigue in Materials Produced by Additive Manufacturing

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Mechanics of Materials".

Deadline for manuscript submissions: closed (20 September 2023) | Viewed by 3032

Special Issue Editor

Prof. Dr. Andrea Avanzini

E-Mail Website
Guest Editor
Department of Mechanical and Industrial Engineering, University of Brescia, via Branze 38, 25123 Brescia, Italy
Interests: fatigue; additive manufacturing; composites; advanced materials; biomedical materials and biomechanics

Special Issue Information

Dear Colleagues,

This Special Issue of Materials concentrates on the fatigue of materials produced by additive manufacturing (AM). Nowadays, AM technologies are an attractive alternative to traditional processes thanks to the possibility of obtaining near-net-shaped complex components for lightweight structures. Despite the disrupting potential, the widespread diffusion of AM for structural applications could be hindered by the current incomplete knowledge about the long-term reliability of additively manufactured products. While the portfolio of new materials and technologies for AM is expanding rapidly, the task of assessing fatigue resistance for AM materials remains particularly challenging due to the number of processing and post-processing parameters involved. Therefore, I would like to invite you to contribute to this Special Issue on “FATIGUE OF MATERIALS PRODUCED BY ADDITIVE MANUFACTURING”. The aim of the Special Issue is to show the recent state-of-the-art in this field, providing novel data on fatigue properties of polymers, composites, metal alloys, or new materials, including architected cellular structures, produced by AM.

Research topics of interest include investigations on correlations between the response of materials to cyclic loading and the technology employed, with associated microstructure, defect types, and surface finish. Comparative analysis on the influence of different AM or conventional processing and post-processing routes are also welcome, as well as highly focused reviews or perspective analyses on specific materials.

Prof. Dr. Andrea Avanzini
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • fatigue
  • additive manufacturing
  • metals
  • polymers
  • composites
  • architected materials
  • heat treatments

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Published Papers (3 papers)

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Research

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21 pages, 71177 KiB  
Article
Low-Cycle Fatigue Behavior of Wire and Arc Additively Manufactured Ti-6Al-4V Material
by Sebastian Springer, Martin Leitner, Thomas Gruber, Bernd Oberwinkler, Michael Lasnik and Florian Grün
Materials 2023, 16(18), 6083; https://doi.org/10.3390/ma16186083 - 5 Sep 2023
Cited by 2 | Viewed by 1384
Abstract
Additive manufacturing (AM) techniques, such as wire arc additive manufacturing (WAAM), offer unique advantages in producing large, complex structures with reduced lead time and material waste. However, their application in fatigue-critical applications requires a thorough understanding of the material properties and behavior. Due [...] Read more.
Additive manufacturing (AM) techniques, such as wire arc additive manufacturing (WAAM), offer unique advantages in producing large, complex structures with reduced lead time and material waste. However, their application in fatigue-critical applications requires a thorough understanding of the material properties and behavior. Due to the layered nature of the manufacturing process, WAAM structures have different microstructures and mechanical properties compared to their substrate counterparts. This study investigated the mechanical behavior and fatigue performance of Ti-6Al-4V fabricated using WAAM compared to the substrate material. Tensile and low-cycle fatigue (LCF) tests were conducted on both materials, and the microstructure was analyzed using optical microscopy and scanning electron microscopy (SEM). The results showed that the WAAM material has a coarser and more heterogeneous grain structure, an increased amount of defects, and lower ultimate tensile strength and smaller elongation at fracture. Furthermore, strain-controlled LCF tests revealed a lower fatigue strength of the WAAM material compared to the substrate, with crack initiation occurring at pores in the specimen rather than microstructural features. Experimental data were used to fit the Ramberg–Osgood model for cyclic deformation behavior and the Manson–Coffin–Basquin model for strain-life curves. The fitted models were subsequently used to compare the two material conditions with other AM processes. In general, the quasi-static properties of WAAM material were found to be lower than those of powder-based processes like selective laser melting or electron beam melting due to smaller cooling rates within the WAAM process. Finally, two simplified estimation models for the strain-life relationship were compared to the experimentally fitted Manson–Coffin–Basquin parameters. The results showed that the simple “universal material law” is applicable and can be used for a quick and simple estimation of the material behavior in cyclic loading conditions. Overall, this study highlights the importance of understanding the mechanical behavior and fatigue performance of WAAM structures compared to their substrate counterparts, as well as the need for further research to improve the understanding of the effects of WAAM process parameters on the mechanical properties and fatigue performance of the fabricated structures. Full article
(This article belongs to the Special Issue Fatigue in Materials Produced by Additive Manufacturing)
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16 pages, 5165 KiB  
Article
Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy
by Muhammad Shamir, Xiang Zhang, Abdul Khadar Syed and Wayne Sadler
Materials 2023, 16(15), 5355; https://doi.org/10.3390/ma16155355 - 30 Jul 2023
Cited by 8 | Viewed by 1350
Abstract
This paper reports the effect of as-deposited surface conditions on the fatigue strength of an additively manufactured titanium alloy, Ti-6Al-4V (WAAM Ti64). First, the local stress concentration caused by the surface waviness was quantified using a metrology technique and computer modelling. Fatigue tests [...] Read more.
This paper reports the effect of as-deposited surface conditions on the fatigue strength of an additively manufactured titanium alloy, Ti-6Al-4V (WAAM Ti64). First, the local stress concentration caused by the surface waviness was quantified using a metrology technique and computer modelling. Fatigue tests were conducted under bending loads at a cyclic load ratio of 0.1. The applicability of two predictive methods was the focus of this study. The traditional notch stress method was unable to predict the correct S–N curve trend slope, which could be attributed to the early crack initiation from the troughs on the as-built surface, with crack propagation being the dominant failure mechanism. By treating the troughs as small cracks, the fracture mechanics approach delivered good predictions at every applied stress level. Surface machining and polishing may not always be practical or required; it depends on the applications and service load levels. This research demonstrated that the fracture mechanics approach can be used for predicting the fatigue life of WAAM titanium alloys in as-built conditions and, hence, can be a tool for decision making on the level of surface machining. Full article
(This article belongs to the Special Issue Fatigue in Materials Produced by Additive Manufacturing)
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Review

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26 pages, 4932 KiB  
Review
Fatigue Behavior of Additively Manufactured Stainless Steel 316L
by Andrea Avanzini
Materials 2023, 16(1), 65; https://doi.org/10.3390/ma16010065 - 21 Dec 2022
Cited by 27 | Viewed by 4148
Abstract
316L stainless steel is the material of choice for several critical applications in which a combination of mechanical strength and resistance to corrosion is required, as in the biomedical field. Additive Manufacturing (AM) technologies can pave the way to new design solutions, but [...] Read more.
316L stainless steel is the material of choice for several critical applications in which a combination of mechanical strength and resistance to corrosion is required, as in the biomedical field. Additive Manufacturing (AM) technologies can pave the way to new design solutions, but microstructure, defect types, and surface characteristics are substantially different in comparison to traditional processing routes, making the assessment of the long-term durability of AM materials and components a crucial aspect. In this paper a thorough review is presented of the relatively large body of recent literature devoted to investigations on fatigue of AM 316L, focusing on the comparison between different AM technologies and conventional processes and on the influence of processing and post-processing aspects in terms of fatigue strength and lifetime. Overall fatigue data are quite scattered, but the dependency of fatigue performances on surface finish, building orientation, and type of heat treatment can be clearly appreciated, as well as the influence of different printing processes. A critical discussion on the different testing approaches presented in the literature is also provided, highlighting the need for shared experimental test protocols and data presentation in order to better understand the complex correlations between fatigue behavior and processing parameters. Full article
(This article belongs to the Special Issue Fatigue in Materials Produced by Additive Manufacturing)
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