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Metals
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Fatigue Behaviour of Additive Manufactured Metallic Materials
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Fatigue Behaviour of Additive Manufactured Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (30 April 2022) | Viewed by 18611

Special Issue Editors

Prof. Dr. Yves Nadot

E-Mail Website
Guest Editor
Institut Pprime, ISAE-ENSMA, CNRS, Université de Poitiers, Poitiers, France
Interests: multiaxial fatigue from defect: experimental approach to understand the role of defect size, type, position, morphology and loading; ‘defect stress gradient’ criterion approach to draw ‘fatigue defect size map’ from 3D image (µCT or process simulation) at the scale of the component; additive manufacturing materials and cast materials
Prof. Dr. Jean-Yves Buffière

E-Mail Website1 Website2
Guest Editor
MATEIS Laboratory, INSA Lyon, 69100 Villeurbanne, France
Interests: characterization of internal fatigue cracks; synchrotron X-ray tomography; in situ experiments
Prof. Dr. Franck Morel

E-Mail Website1 Website2
Guest Editor
Arts et Metiers Institute of Technology, LAMPA, HESAM Université, F-49035 Angers, France
Interests: multiaxial fatigue of materials and structures; manufacturing process (additive manufacturing, machining, forging, casting) and fatigue; effects of microstructure and defects on fatigue; probabilistic modelling approach; gradient and size effects from specimen to structure

Special Issue Information

Dear Colleagues,

Additively Manufactured metals are produced for several industries (biomedical, aeronautics, energy, …) using different alloys (Steel, Aluminum, Titanium, …). Aeronautical components such as TiAl turbine blades are certified to fly and Titanium dental implants are regularly produced. One of the major characteristics of Additively Manufactured components is the direct link between the production of the final component and the initial CAD design. The design constraints are also relatively limited compared to more traditional processes, allowing to produce optimized geometries. Like for all other manufacturing processes, a qualification stage must be carefully developed in order to insure that the final component is within the specifications related to six major characteristics: density, 3D geometry, surface roughness, residual stresses, microstructure and mechanical properties. Other specifications can be requested depending on the final application. When the component is submitted to fatigue loading, a special attention must be paid to the surface roughness, the defect population, residual stresses and microstructure.

This special issue will focus on the fatigue behavior of additively manufactured metals with a special attention to the following parameters: microstructure, defect population, roughness and residual stresses. Different modelling strategies (deterministic and probabilistic) regarding crack initiation and growth from surface, defects or microstructural inhomogeneities will also be addressed. As the metal produced is inherited from this process, the relation to the process parameter must be clearly specified. Heat treatment must also be considered as a major parameter (HIP, stress release, …). Each of these parameters can have an influence on the fatigue behavior and this influence can vary from a material to another (Titanium appears to be more sensitive to defects compared to Aluminum for example), from a process to another (SLM generates more internal defects compared to WAAM) and also depending on the fatigue regime (Crack initiation shifts from the surface to the bulk when the stress level is low enough to reach fatigue lives larger than 108-109 cycles)

The objectives of this special issue are to present recent advances from both experimental and modelling perspectives in order to help the emergence of important new topics and approaches in this fast evolving field.

Prof. Dr. Yves Nadot
Prof. Dr. Jean-Yves Buffière
Prof. Dr. Franck Morel
Guest Editors

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. Metals is an international peer-reviewed open access monthly 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

  • Additive manufacturing materials
  • Fatigue loading
  • Microstructure
  • Residual Stresses
  • Micro defect
  • Lack of fusion
  • Key hole porosity
  • Gas pore
  • Artificial defect
  • As-Built surface
  • Roughness

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Published Papers (6 papers)

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Research

14 pages, 6263 KiB  
Article
A Numerical Study into the Effect of Machining on the Interaction between Surface Roughness and Surface Breaking Defects on the Durability of WAAM Ti-6Al-4V Parts
by Daren Peng, Rhys Jones, Andrew S. M. Ang, Victor Champagne, Aaron Birt and Alex Michelson
Metals 2022, 12(7), 1121; https://doi.org/10.3390/met12071121 - 29 Jun 2022
Cited by 5 | Viewed by 2003
Abstract
The airworthiness certification of military aircraft requires a durability analysis be performed using linear elastic fracture mechanics (LEFM). Furthermore, such analyses need to use a valid small crack growth equation. This paper focuses on the effect of rough surfaces and the effect of [...] Read more.
The airworthiness certification of military aircraft requires a durability analysis be performed using linear elastic fracture mechanics (LEFM). Furthermore, such analyses need to use a valid small crack growth equation. This paper focuses on the effect of rough surfaces and the effect of machining the surface on the durability of AM parts using LEFM and a valid small crack growth equation for the material. To this end, this paper analyses the effect of surface roughness on wire and arc additively manufactured (WAAM) Ti-6Al-4V titanium parts and the effect of machining on the durability of a part. The analysis reveals that the life of the component is a relatively strong function of the degree of surface roughness, and that the durability of a specimen is a strong function of the local radius of the curvature of the trough. It also appears that surfaces with tall narrow roughness will not overly benefit from partial machining of the surface. Full article
(This article belongs to the Special Issue Fatigue Behaviour of Additive Manufactured Metallic Materials)
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25 pages, 3467 KiB  
Article
Analysis of Fatigue Strength of L-PBF AlSi10Mg with Different Surface Post-Processes: Effect of Residual Stresses
by Francesco Sausto, Christian Tezzele and Stefano Beretta
Metals 2022, 12(6), 898; https://doi.org/10.3390/met12060898 - 25 May 2022
Cited by 24 | Viewed by 3859
Abstract
Space and aerospace industries has been starting in the recent years the replacement process of parts and components obtained by traditional manufacturing processes with those produced by Additive Manufacturing (AM). The complexity of the obtainable parts makes, in general, challenging the superficial post [...] Read more.
Space and aerospace industries has been starting in the recent years the replacement process of parts and components obtained by traditional manufacturing processes with those produced by Additive Manufacturing (AM). The complexity of the obtainable parts makes, in general, challenging the superficial post processing of some zones, making a stringent requirement the investigation of the fatigue performances of components with rough superficial state or machined. The aim of this work is then to analyse and compare the fatigue performances of an additively manufactured (AMed) AlSi10Mg material considering both the effects of the manufacturing defects and residual stresses related to three different superficial states, namely machined, net-shape and sandblasted. The residual stress profiles of the three superficial states were found to play a key role in determining the fatigue properties of the analysed material, while the manufacturing defects at the failure origin were found to be comparable among the three series. To take into account the combined effect of residual stresses and manufacturing defects a fracture mechanics approach was considered for the estimation of the fatigue performances in both infinite and finite life regimes. It was found that by considering the nominal measured residual stress profiles in the fracture mechanics model the estimations were satisfactory compared to the experimental data-point. To increase the accuracy of the fatigue life estimations a series of numerical analyses were performed aimed to investigate the residual stresses relaxation during the cyclic loading. The adoption of the relaxed residual stress profiles in the fracture mechanics model resulted in good estimations respect to the experimental data-points, highlighting the necessity in adopting such developed approaches during the design phase of AM parts and components. Full article
(This article belongs to the Special Issue Fatigue Behaviour of Additive Manufactured Metallic Materials)
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21 pages, 41438 KiB  
Article
Very High Cycle Fatigue Investigations on the Fatigue Strength of Additive Manufactured and Conventionally Wrought Inconel 718 at 873 K
by Alexander Schmiedel, Christina Burkhardt, Sebastian Henkel, Anja Weidner and Horst Biermann
Metals 2021, 11(11), 1682; https://doi.org/10.3390/met11111682 - 22 Oct 2021
Cited by 10 | Viewed by 3777
Abstract
The fatigue lives of additively manufactured (AM) Inconel 718 (IN718) produced by selective electron beam melting and conventional wrought material as reference conditions were studied in the very high cycle fatigue regime under fully reversed loading (R = −1) at the elevated temperature [...] Read more.
The fatigue lives of additively manufactured (AM) Inconel 718 (IN718) produced by selective electron beam melting and conventional wrought material as reference conditions were studied in the very high cycle fatigue regime under fully reversed loading (R = −1) at the elevated temperature of 873 K using an ultrasonic fatigue testing system. The fatigue lives of the AM material were significantly reduced compared to the wrought material, which is discussed in relation to the microstructure and a fractographical analysis. The additively manufactured material showed large columnar grains with a favoured orientation to the building direction and porosity, whereas the wrought material showed a fine-grained structure with no significant texture, but had Nb- and Ti-rich non-metallic inclusions. Crystallographic crack initiation as well as crack initiation from the surface or internal defects were observed for the AM and the wrought IN718, respectively. Full article
(This article belongs to the Special Issue Fatigue Behaviour of Additive Manufactured Metallic Materials)
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17 pages, 11132 KiB  
Article
Effect of As-Built and Ground Surfaces on the Fatigue Properties of AlSi10Mg Alloy Produced by Additive Manufacturing
by Julius Noel Domfang Ngnekou, Yves Nadot, Gilbert Henaff, Julien Nicolai and Lionel Ridosz
Metals 2021, 11(9), 1432; https://doi.org/10.3390/met11091432 - 10 Sep 2021
Cited by 10 | Viewed by 2471
Abstract
The present work concerns the influence of surface (machined, as-built) on the fatigue resistance of AlSi10Mg produced by a powder-bed laser process. The competition between defects and surface roughness is assessed by using Kitagawa-type diagrams. Samples are printed along three directions: 0°, 45° [...] Read more.
The present work concerns the influence of surface (machined, as-built) on the fatigue resistance of AlSi10Mg produced by a powder-bed laser process. The competition between defects and surface roughness is assessed by using Kitagawa-type diagrams. Samples are printed along three directions: 0°, 45° and 90°. After axial fatigue tests with a load ratio of R = −1, all the fracture surfaces are carefully analysed. The initiation sites can be (i) a defect, (ii) the surface roughness, (iii) the surface ripple. The results indicate that ground surfaces lead to the same fatigue life as as-built surfaces. It is also shown that T6 treatment improves the fatigue resistance. However, when specimen surfaces are as-built or ground, it is difficult to correlate the fatigue results with ‘isolated defect size analysis’ neither roughness parameter for an as-built surface. Therefore, microstructure, residual stresses or multiple initiation should be further analysed to understand the results. Full article
(This article belongs to the Special Issue Fatigue Behaviour of Additive Manufactured Metallic Materials)
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17 pages, 4739 KiB  
Article
Towards a Methodology for Component Design of Metallic AM Parts Subjected to Cyclic Loading
by Uwe Zerbst, Mauro Madia, Giovanni Bruno and Kai Hilgenberg
Metals 2021, 11(5), 709; https://doi.org/10.3390/met11050709 - 26 Apr 2021
Cited by 6 | Viewed by 2407
Abstract
The safe fatigue design of metallic components fabricated by additive manufacturing (AM) is still a largely unsolved problem. This is primarily due to (a) a significant inhomogeneity of the material properties across the component; (b) defects such as porosity and lack of fusion [...] Read more.
The safe fatigue design of metallic components fabricated by additive manufacturing (AM) is still a largely unsolved problem. This is primarily due to (a) a significant inhomogeneity of the material properties across the component; (b) defects such as porosity and lack of fusion as well as pronounced surface roughness of the as-built components; and (c) residual stresses, which are very often present in the as-built parts and need to be removed by post-fabrication treatments. Such morphological and microstructural features are very different than in conventionally manufactured parts and play a much bigger role in determining the fatigue life. The above problems require specific solutions with respect to the identification of the critical (failure) sites in AM fabricated components. Moreover, the generation of representative test specimens characterized by similar temperature cycles needs to be guaranteed if one wants to reproducibly identify the critical sites and establish fatigue assessment methods taking into account the effect of defects on crack initiation and early propagation. The latter requires fracture mechanics-based approaches which, unlike common methodologies, cover the specific characteristics of so-called short fatigue cracks. This paper provides a discussion of all these aspects with special focus on components manufactured by laser powder bed fusion (L-PBF). It shows how to adapt existing solutions, identifies fields where there are still gaps, and discusses proposals for potential improvement of the damage tolerance design of L-PBF components. Full article
(This article belongs to the Special Issue Fatigue Behaviour of Additive Manufactured Metallic Materials)
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23 pages, 9359 KiB  
Article
Effect of Platform Temperature and Post-Processing Heat Treatment on the Fatigue Life of Additively Manufactured AlSi7Mg Alloy
by Luiz Felipe Leitao Martins, Paul R. Provencher, Mathieu Brochu and Myriam Brochu
Metals 2021, 11(5), 679; https://doi.org/10.3390/met11050679 - 21 Apr 2021
Cited by 8 | Viewed by 2620
Abstract
The effect of platform temperature combined with a T5 heat treatment on the fatigue life of additively manufactured aluminum alloy AlSi7Mg was characterized and understood. High-cycle fatigue tests were carried out on samples built with four platform temperatures (35 °C, 60 °C, 80 [...] Read more.
The effect of platform temperature combined with a T5 heat treatment on the fatigue life of additively manufactured aluminum alloy AlSi7Mg was characterized and understood. High-cycle fatigue tests were carried out on samples built with four platform temperatures (35 °C, 60 °C, 80 °C and 200 °C) and post-processing heat treatment strategies (F and T5). Microstructural and fractographic observations combined with microhardness measurements were performed. A log-normal statistical distribution regressed with 90% B-basis probabilities of survival revealed that specimens produced on a platform maintained at 80 °C and post-processed with a T5 heat treatment presented the highest fatigue life among the conditions tested. Precipitation of silicon within the aluminum cells during the T5 heat treatment is the proposed explanation for the improved fatigue life of the T5 samples. In the as-built condition, specimens produced at 200 °C were found to be less resistant to fatigue than the specimens built at lower temperatures. The coarser microstructure and lowest microhardness resulting from high-temperature manufacturing explain this reduced fatigue strength. All fatigue cracks initiated from manufacturing discontinuities. This led to a fatigue life prediction model based upon linear elastic fracture mechanics. The model was fitted to the experimental results of the F and T5 samples separately. With the exception of the 35 °C—T5 specimens, the predicted fatigue lives agree with the experimental results and literature. Full article
(This article belongs to the Special Issue Fatigue Behaviour of Additive Manufactured Metallic Materials)
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