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Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes

Lauren Ednie, A.A. Antonysamy, L. Parimi, M. Mani, M. Thomas Orcid Logo, Robert Lancaster Orcid Logo

Journal of Materials Research and Technology, Volume: 31, Pages: 1337 - 1354

Swansea University Authors: Lauren Ednie, Robert Lancaster Orcid Logo

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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...

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Published in: Journal of Materials Research and Technology
ISSN: 2238-7854
Published: Elsevier BV 2024
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URI: https://cronfa.swan.ac.uk/Record/cronfa66898
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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. 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The provision of a research bursary, materials and supporting information from GKN Additive is gratefully acknowledged. 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spelling v2 66898 2024-06-26 Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes 8d34318252ba316f7887d108cfb15544 Lauren Ednie Lauren Ednie true false e1a1b126acd3e4ff734691ec34967f29 0000-0002-1365-6944 Robert Lancaster Robert Lancaster true false 2024-06-26 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. Journal Article Journal of Materials Research and Technology 31 1337 1354 Elsevier BV 2238-7854 Ti-6Al–4V, Additive manufacture, Fatigue, Surface finish 1 7 2024 2024-07-01 10.1016/j.jmrt.2024.06.168 http://dx.doi.org/10.1016/j.jmrt.2024.06.168 COLLEGE NANME COLLEGE CODE Swansea University SU College/Department paid the OA fee 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. 2024-07-03T10:38:11.2221456 2024-06-26T13:13:07.5672881 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Lauren Ednie 1 A.A. Antonysamy 2 L. Parimi 3 M. Mani 4 M. Thomas 0000-0002-9804-3775 5 Robert Lancaster 0000-0002-1365-6944 6 66898__30800__70e2cf77361d423b86a163289fdf7c68.pdf 66898.VoR.pdf 2024-07-03T10:35:24.2132050 Output 26288695 application/pdf Version of Record true © 2024 The Authors. This is an open access article under the CC BY-NC-ND license. true eng http://creativecommons.org/licenses/by-nc-nd/4.0/
title Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
spellingShingle Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
Lauren Ednie
Robert Lancaster
title_short Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
title_full Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
title_fullStr Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
title_full_unstemmed Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
title_sort Understanding the fatigue behaviour of Ti–6Al–4V manufactured via various additive processes
author_id_str_mv 8d34318252ba316f7887d108cfb15544
e1a1b126acd3e4ff734691ec34967f29
author_id_fullname_str_mv 8d34318252ba316f7887d108cfb15544_***_Lauren Ednie
e1a1b126acd3e4ff734691ec34967f29_***_Robert Lancaster
author Lauren Ednie
Robert Lancaster
author2 Lauren Ednie
A.A. Antonysamy
L. Parimi
M. Mani
M. Thomas
Robert Lancaster
format Journal article
container_title Journal of Materials Research and Technology
container_volume 31
container_start_page 1337
publishDate 2024
institution Swansea University
issn 2238-7854
doi_str_mv 10.1016/j.jmrt.2024.06.168
publisher Elsevier BV
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
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department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
url http://dx.doi.org/10.1016/j.jmrt.2024.06.168
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description 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.
published_date 2024-07-01T10:38:10Z
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