On the size-dependent fatigue behaviour of laser powder bed fusion Ti-6Al-4V

Jieming S Zhang; Yuanbo T. Tang; Ruining  Jin; Andrew  Lui; Patrick S. Grant; Enrique Alabort; Alan C. F. Cocks; Roger Reed

doi:10.1016/j.addma.2023.103922

On the size-dependent fatigue behaviour of laser powder bed fusion Ti-6Al-4V

Jieming S Zhang^*, Yuanbo T. Tang, Ruining Jin, Andrew Lui, Patrick S. Grant, Enrique Alabort, Alan C. F. Cocks, Roger Reed

^*Corresponding author for this work

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Abstract

A sample size effect which influences the fatigue behaviour of laser powder bed fusion Ti-6Al-4V is identified and quantified. Two cylindrical samples are considered: ∅ 1.3 mm and ∅ 2.0 mm. The larger specimen demonstrates better fatigue resistance particularly in the high-cycle regime, with the differing surface roughness contributing to this effect. It is also confirmed that processing-induced porosity can compromise the fatigue performance even when the initiation sites are surface defects. The larger contribution of porosity to the fatigue fracture process of the larger specimen results in a higher scatter in the fatigue life. Differences in microstructure do not seem to contribute strongly to the variation in fatigue properties of the two specimens, but we present some evidence that the coarser microstructure of the larger specimen promotes a stronger tolerance to defects and induces more tortuous crack paths which hinders fatigue crack growth.

Original language	English
Article number	103922
Number of pages	15
Journal	Additive Manufacturing
Volume	79
Issue number	5
Early online date	12 Dec 2023
DOIs	https://doi.org/10.1016/j.addma.2023.103922
Publication status	Published - 5 Jan 2024

Bibliographical note

Acknowledgments:
Jieming S. Zhang would like to thank Prof. Andrew Horsfield and Prof. David Dye for their inspirations to start this DPhil study. Helpful comments from Prof. Marco Simonelli of University of Nottingham, Dr. Enzo Liotti, Dr. Yun Deng, Dr. Insung Han, Dr. Joseph N. Ghoussoub, and Prof. D. Graham McCartney of University of Oxford are acknowledged. The authors are grateful for the funding from Alloyed Ltd. and Innovate UK 43749. Yuanbo T. Tang and Roger C. Reed acknowledge support from the Henry Royce Institute for Advanced Materials, funded through EPSRC, United Kingdom grants (EP/R00661X/1) and (EP/X527257/1).

Keywords

Titanium
Laser powder bed fusion
Fatigue
Size-dependency
X-ray computed tomography

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abstract = "A sample size effect which influences the fatigue behaviour of laser powder bed fusion Ti-6Al-4V is identified and quantified. Two cylindrical samples are considered: ∅ 1.3 mm and ∅ 2.0 mm. The larger specimen demonstrates better fatigue resistance particularly in the high-cycle regime, with the differing surface roughness contributing to this effect. It is also confirmed that processing-induced porosity can compromise the fatigue performance even when the initiation sites are surface defects. The larger contribution of porosity to the fatigue fracture process of the larger specimen results in a higher scatter in the fatigue life. Differences in microstructure do not seem to contribute strongly to the variation in fatigue properties of the two specimens, but we present some evidence that the coarser microstructure of the larger specimen promotes a stronger tolerance to defects and induces more tortuous crack paths which hinders fatigue crack growth.",

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author = "Zhang, {Jieming S} and Tang, {Yuanbo T.} and Ruining Jin and Andrew Lui and Grant, {Patrick S.} and Enrique Alabort and Cocks, {Alan C. F.} and Roger Reed",

note = "Acknowledgments: Jieming S. Zhang would like to thank Prof. Andrew Horsfield and Prof. David Dye for their inspirations to start this DPhil study. Helpful comments from Prof. Marco Simonelli of University of Nottingham, Dr. Enzo Liotti, Dr. Yun Deng, Dr. Insung Han, Dr. Joseph N. Ghoussoub, and Prof. D. Graham McCartney of University of Oxford are acknowledged. The authors are grateful for the funding from Alloyed Ltd. and Innovate UK 43749. Yuanbo T. Tang and Roger C. Reed acknowledge support from the Henry Royce Institute for Advanced Materials, funded through EPSRC, United Kingdom grants (EP/R00661X/1) and (EP/X527257/1).",

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AU - Cocks, Alan C. F.

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N2 - A sample size effect which influences the fatigue behaviour of laser powder bed fusion Ti-6Al-4V is identified and quantified. Two cylindrical samples are considered: ∅ 1.3 mm and ∅ 2.0 mm. The larger specimen demonstrates better fatigue resistance particularly in the high-cycle regime, with the differing surface roughness contributing to this effect. It is also confirmed that processing-induced porosity can compromise the fatigue performance even when the initiation sites are surface defects. The larger contribution of porosity to the fatigue fracture process of the larger specimen results in a higher scatter in the fatigue life. Differences in microstructure do not seem to contribute strongly to the variation in fatigue properties of the two specimens, but we present some evidence that the coarser microstructure of the larger specimen promotes a stronger tolerance to defects and induces more tortuous crack paths which hinders fatigue crack growth.

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On the size-dependent fatigue behaviour of laser powder bed fusion Ti-6Al-4V

Abstract

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Keywords

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