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Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
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Robert Lancaster
Journal of Materials Research and Technology, Volume: 31, Pages: 1337 - 1354
Swansea University Authors:
Lauren Ednie, Robert Lancaster
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© 2024 The Authors. This is an open access article under the CC BY-NC-ND license.
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DOI (Published version): 10.1016/j.jmrt.2024.06.168
Abstract
Additive Manufacturing (AM) is receiving widespread attention from both industry and academia who are looking to benefit from the numerous advantageous possibilities that AM processes have to offer, such as the potential to design and produce highly complex bespoke geometries with minimal material w...
| Published in: | Journal of Materials Research and Technology |
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| ISSN: | 2238-7854 |
| Published: |
Elsevier BV
2024
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| Online Access: |
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| URI: | https://cronfa.swan.ac.uk/Record/cronfa66898 |
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| Abstract: |
Additive Manufacturing (AM) is receiving widespread attention from both industry and academia who are looking to benefit from the numerous advantageous possibilities that AM processes have to offer, such as the potential to design and produce highly complex bespoke geometries with minimal material wastage. Yet, despite this, AM also has some drawbacks. Some of the most significant include the presence of process-induced defects and the inherent surface roughness of an AM built component, both of which can have a considerable influence on the mechanical properties of the final product. This research will investigate the role of an as-built surface on the fatigue properties of AM Ti-6Al-4V manufactured by electron beam melting (EBM), laser powder bed fusion (L-PBF) and laser metal deposition with wire (LMD-w). Fatigue results have been generated alongside advanced surface profilometry, microstructural, defect and fractographic analyses that have revealed that whilst the surface roughness in the majority of instances is the primary factor impacting the fatigue performance on AM material, it cannot be considered alone. It was found that the inherent as-built (AB) surface finish was significantly different across the various AM processes, inducing a range of effective stress concentrations and thus, a contrasting impact on the resulting fatigue performance. Results from each variant have been compared against a machined and polished equivalent, to provide a further consideration as to whether the as-built surface would be suffice from a time and economical viewpoint. Statistical analysis of the generated results also allowed for an extrapolation of predicted fatigue lives in the very high cycle regime for the alternative AM Ti-6Al-4V variants. |
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| Keywords: |
Ti-6Al–4V, Additive manufacture, Fatigue, Surface finish |
| College: |
Faculty of Science and Engineering |
| Funders: |
The current research was funded by the Materials and Manufacturing Academy, M2A, supported by the European Social fund through the Welsh Government. The provision of a research bursary, materials and supporting information from GKN Additive is gratefully acknowledged. The assistance provided by the Swansea University AIM Facility and the Welsh Coating and Printing Centre, which was funded in part by the EPSRC, are also much appreciated. |
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