Fatigue Performance of Laser Additive Manufactured Ti-6al-4V in Very High Cycle Fatigue Regime Up to 1E9 Cycles PDF Download
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Author: Eric Wycisk
Publisher:
ISBN:
Category :
Languages : en
Pages :
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Book Description
Additive manufacturing technologies are in the process of establishing themselves as an alternative production technology to conventional manufacturing, such as casting or milling. Especially laser additive manufacturing (LAM) enables the production of metallic parts with mechanical properties comparable to conventionally manufactured components. Due to the high geometrical freedom in LAM, the technology enables the production of ultra-light weight designs, and therefore gains increasing importance in aircraft and space industry. The high quality standards of these industries demand predictability of material properties for static and dynamic load cases. However, fatigue properties especially in the very high cycle fatigue (VHCF) regime until 109 cycles have not been sufficiently determined yet. Therefore, this paper presents an analysis of fatigue properties of laser additive manufactured Ti-6Al-4V under cyclic tension-tension until 107 cycles and tension-compression load until 109 cycles. For the analysis of laser additive manufactured titanium alloy Ti-6Al-4V, Woehler fatigue tests under tension-tension and tension-compression were carried out in the high cycle and VHCF regime. Specimens in stress-relieved as well as hot-isostatic-pressed conditions were analyzed regarding crack initiation site, mean stress sensitivity, and overall fatigue performance. The determined fatigue properties show values in the range of conventionally manufactured Ti-6Al-4V with particularly good performance for hot-isostatic-pressed additive-manufactured material. For all conditions, the results show no conventional fatigue limit but a constant increase in fatigue life with decreasing loads. No effects of test frequency on life span could be determined. However, independently of testing principle, a shift of crack initiation from surface to internal initiation could be observed with increasing cycles to failure.
Author: Eric Wycisk
Publisher:
ISBN:
Category :
Languages : en
Pages :
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Book Description
Additive manufacturing technologies are in the process of establishing themselves as an alternative production technology to conventional manufacturing, such as casting or milling. Especially laser additive manufacturing (LAM) enables the production of metallic parts with mechanical properties comparable to conventionally manufactured components. Due to the high geometrical freedom in LAM, the technology enables the production of ultra-light weight designs, and therefore gains increasing importance in aircraft and space industry. The high quality standards of these industries demand predictability of material properties for static and dynamic load cases. However, fatigue properties especially in the very high cycle fatigue (VHCF) regime until 109 cycles have not been sufficiently determined yet. Therefore, this paper presents an analysis of fatigue properties of laser additive manufactured Ti-6Al-4V under cyclic tension-tension until 107 cycles and tension-compression load until 109 cycles. For the analysis of laser additive manufactured titanium alloy Ti-6Al-4V, Woehler fatigue tests under tension-tension and tension-compression were carried out in the high cycle and VHCF regime. Specimens in stress-relieved as well as hot-isostatic-pressed conditions were analyzed regarding crack initiation site, mean stress sensitivity, and overall fatigue performance. The determined fatigue properties show values in the range of conventionally manufactured Ti-6Al-4V with particularly good performance for hot-isostatic-pressed additive-manufactured material. For all conditions, the results show no conventional fatigue limit but a constant increase in fatigue life with decreasing loads. No effects of test frequency on life span could be determined. However, independently of testing principle, a shift of crack initiation from surface to internal initiation could be observed with increasing cycles to failure.
Author: Mustafa Mamduh Mustafa Awd
Publisher: Springer Nature
ISBN: 3658402377
Category : Computers
Languages : en
Pages : 289
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Book Description
Fatigue failure of structures used in transportation, industry, medical equipment, and electronic components needs to build a link between cutting-edge experimental characterization and probabilistically grounded numerical and artificially intelligent tools. The physics involved in this process chain is computationally prohibitive to comprehend using traditional computation methods. Using machine learning and Bayesian statistics, a defect-correlated estimate of fatigue strength was developed. Fatigue, which is a random variable, is studied in a Bayesian-based machine learning algorithm. The stress-life model was used based on the compatibility condition of life and load distributions. The defect-correlated assessment of fatigue strength was established using the proposed machine learning and Bayesian statistics algorithms. It enabled the mapping of structural and process-induced fatigue characteristics into a geometry-independent load density chart across a wide range of fatigue regimes.
Author: Shafaqat Siddique
Publisher: Springer
ISBN: 3658234253
Category : Technology & Engineering
Languages : en
Pages : 162
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Book Description
Selective laser melting (SLM) has established itself as the most prominent additive manufacturing (AM) process for metallic structures in aerospace, automotive and medical industries. For a reliable employment of this process, it has to conform to the demanding requirements of these industries in terms of quasistatic and, especially, fatigue performance. Shafaqat Siddique identifies the influence of SLM processing conditions on the microstructural features, and their corresponding influence on the mechanical behavior of the processed AlSi12 alloy structures. The author also gives insight into integrated manufacturing by combining conventional and SLM processes to get the synergic benefits. Requirements for fatigue-resistant designs in additive manufacturing are highlighted, and a novel method is developed for agile fatigue life prediction. About the Author Shafaqat Siddique worked as Scientific Assistant at TU Dortmund University, Department of Materials Test Engineering (WPT), headed by Prof. Dr.-Ing. Frank Walther, and completed his Ph.D. research in cooperation with Laser Zentrum Nord (LZN) in Hamburg. He continues his post-doctoral research at TU Dortmund University, Germany.
Author: Filippo Berto
Publisher: Elsevier
ISBN: 0323998313
Category : Technology & Engineering
Languages : en
Pages : 321
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Book Description
Fatigue in Additive Manufactured Metals provides a brief overview of the fundamental mechanics involved in metal fatigue and fracture, assesses the unique properties of additive manufactured metals, and provides an in-depth exploration of how and why fatigue occurs in additive manufactured metals. Additional sections cover solutions for preventing it, best-practice design methods, and more. The book recommends cutting-edge evidence-based approaches for designing longer lasting additive manufactured metals, discusses the latest trends in the field and the various aspects of low cycle fatigue, and looks at both post-treatment and manufacturing process-based solutions. By providing international standards and testing procedures of additive manufactured metal parts and discussing the environmental impacts of additive manufacturing of metals and outlining simulation and modeling scenarios, this book is an ideal resource for users in industry. - Discusses the underlying mechanisms controlling the fatigue behavior of additive manufactured metal components as well as how to improve the fatigue life of these components via both manufacturing processes and post-processing - Studies the variability of properties in additive manufactured metals, the effects of different process conditions on mechanical reliability, probabilistic versus deterministic aspects, and more - Outlines nondestructive failure analysis techniques and highlights the effects of unique microstructural characteristics on fatigue in additive manufactured metals
Author: Fedor Fomin
Publisher:
ISBN:
Category : Fatigue
Languages : en
Pages :
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Book Description
This aim of this work is to investigate the fatigue behaviour of laser-welded Ti-6Al-4V titanium alloy in the region of high cycle fatigue. The crack initiation mechanism and the influence of weld defects on fatigue performance were comprehensively studied. A set of post-weld treatments that can mitigate the effect of inherent weld imperfections and thereby extend the fatigue life were analysed. A robust and efficient analytical assessment model for internally-flawed materials has been developed based on a fracture mechanics approach. The developed methodology can be used for the reliability assessment of components with various types of defects, thus enabling a defect-tolerant design of welded structures.
Author: Palmer R. Frye
Publisher:
ISBN:
Category : Additive manufacturing -- Design and construction - Testing
Languages : en
Pages :
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Book Description
Additive Manufacturing (AM) techniques have recently gained popularity for fabrication of parts used in aerospace applications. Some of these parts may be subjected to cyclic loading at very high frequencies, leading to service life requirements exceeding ten-million cycles (>10107 cycles). Therefore, understanding the very high-cycle fatigue (VHCF) behavior of these AM parts is an important step in their design and qualification processes. In this thesis, both high-cycle fatigue (HCF) and VHCF behaviors of Inconel 718, a Ni-base superalloy, manufactured via a Laser Beam-Powder Bed Fusion (LB-PBF) process, are investigated. Uniaxial, fully reversed force-controlled fatigue tests were conducted utilizing a ultrasonic fatigue test system operating at 20 kHz. Specimen fracture surfaces were analyzed using a scanning electron microscope (SEM). Fatigue test specimens were fabricated in two different build orientations, including vertical and 45 degrees (i.e., diagonal) with respect to the build plate, and subjected to a post-process solution annealing and aging heat treatment. In addition, specimens were testing in both the as-built and post-process machined condition. Fatigue response of LB-PBF Inconel 718 was compared to that of wrought Inconel 718. Comparison of the stress-life (S-N) response of LB-PBF Inconel 718 fabricated in the vertical and diagonal build orientations showed almost no discrepancy in fatigue life for the as-built condition. For machined LB-PBF specimens, the effects of build layer orientation were more apparent: fatigue resistance of vertically oriented specimens was superior to diagonally oriented specimens. An increase in fatigue resistance of LB-PBF Inconel 718 was observed for specimens of the machined surface condition due to the removal of surface defects from the as-built surface. AM process induced defects significantly influenced fatigue crack initiation for as-built specimens: all fatigue cracks in as-built specimens originated from either surface micro-notches or sub-surface lack of fusion. Fatigue cracks in all specimens, regardless of build orientation and surface quality, were found to initiate from both specimen surfaces and sub-surface anomalies in the microstructure. Fatigue limit estimation was performed using Murakami's approach, which accounts for AM process induced defects. Additionally, S-N curve fitting was performed using the Basquin equation. Despite the presence of defects seen on VHCF fractures of as-built vertical specimens, the Murakami model proved to be insufficient for the specimens used in this study.
Author: Olawale Samuel Fatoba
Publisher:
ISBN:
Category : Technology
Languages : en
Pages :
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Book Description
Modern industrial applications require materials with special surface properties such as high hardness, wear and corrosion resistance. The performance of material surface under wear and corrosion environments cannot be fulfilled by the conventional surface modifications and coatings. Therefore, different industrial sectors need an alternative technique for enhanced surface properties. The purpose of this is to change or enhance inherent properties of the materials to create new products or improve on existing ones. The most effective and economical engineering solution to prevent or minimize such surface region of a component is done by fiber lasers. Additive manufacturing (AM) is a breaking edge fabrication technique with the possibility of changing the perception of design and manufacturing as a whole. It is well suitable for the building and repairing applications in the aerospace industry which usually requires high level of accuracy and customization of parts which usually employ materials known to pose difficulties in fabrication such as titanium alloys. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defense, and automotive industries.
Author: Harold Luong
Publisher:
ISBN:
Category :
Languages : en
Pages : 196
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Book Description
Author: Magnus Kahlin
Publisher:
ISBN: 9789176855386
Category :
Languages : en
Pages : 0
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Author: R. R. Hilsen
Publisher:
ISBN:
Category : Airplanes
Languages : en
Pages : 14
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Book Description
To determine the effects of various factors on low-cycle fatigue phenomena in connection with space vehicle design, axial tension fatigue tests up to 2000 cycles were conducted on titanium alloy, Ti-6Al-4V, at -423 F. The effects of changing the minimum-to-maximum load ratio and cycling speed for the range tested were slight. The fatigue strength of pressure-welded specimens was within 1 per cent of that of the base metal. Fatigue strengths at -423 F were 65 to 68 per cent higher than those at room temperature.
