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Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy

This paper reports the effect of as-deposited surface conditions on the fatigue strength of an additively manufactured titanium alloy, Ti-6Al-4V (WAAM Ti64). First, the local stress concentration caused by the surface waviness was quantified using a metrology technique and computer modelling. Fatigu...

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Detalles Bibliográficos
Autores principales: Shamir, Muhammad, Zhang, Xiang, Syed, Abdul Khadar, Sadler, Wayne
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10419546/
https://www.ncbi.nlm.nih.gov/pubmed/37570059
http://dx.doi.org/10.3390/ma16155355
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author Shamir, Muhammad
Zhang, Xiang
Syed, Abdul Khadar
Sadler, Wayne
author_facet Shamir, Muhammad
Zhang, Xiang
Syed, Abdul Khadar
Sadler, Wayne
author_sort Shamir, Muhammad
collection PubMed
description This paper reports the effect of as-deposited surface conditions on the fatigue strength of an additively manufactured titanium alloy, Ti-6Al-4V (WAAM Ti64). First, the local stress concentration caused by the surface waviness was quantified using a metrology technique and computer modelling. Fatigue tests were conducted under bending loads at a cyclic load ratio of 0.1. The applicability of two predictive methods was the focus of this study. The traditional notch stress method was unable to predict the correct S–N curve trend slope, which could be attributed to the early crack initiation from the troughs on the as-built surface, with crack propagation being the dominant failure mechanism. By treating the troughs as small cracks, the fracture mechanics approach delivered good predictions at every applied stress level. Surface machining and polishing may not always be practical or required; it depends on the applications and service load levels. This research demonstrated that the fracture mechanics approach can be used for predicting the fatigue life of WAAM titanium alloys in as-built conditions and, hence, can be a tool for decision making on the level of surface machining.
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spelling pubmed-104195462023-08-12 Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy Shamir, Muhammad Zhang, Xiang Syed, Abdul Khadar Sadler, Wayne Materials (Basel) Article This paper reports the effect of as-deposited surface conditions on the fatigue strength of an additively manufactured titanium alloy, Ti-6Al-4V (WAAM Ti64). First, the local stress concentration caused by the surface waviness was quantified using a metrology technique and computer modelling. Fatigue tests were conducted under bending loads at a cyclic load ratio of 0.1. The applicability of two predictive methods was the focus of this study. The traditional notch stress method was unable to predict the correct S–N curve trend slope, which could be attributed to the early crack initiation from the troughs on the as-built surface, with crack propagation being the dominant failure mechanism. By treating the troughs as small cracks, the fracture mechanics approach delivered good predictions at every applied stress level. Surface machining and polishing may not always be practical or required; it depends on the applications and service load levels. This research demonstrated that the fracture mechanics approach can be used for predicting the fatigue life of WAAM titanium alloys in as-built conditions and, hence, can be a tool for decision making on the level of surface machining. MDPI 2023-07-30 /pmc/articles/PMC10419546/ /pubmed/37570059 http://dx.doi.org/10.3390/ma16155355 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Shamir, Muhammad
Zhang, Xiang
Syed, Abdul Khadar
Sadler, Wayne
Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy
title Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy
title_full Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy
title_fullStr Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy
title_full_unstemmed Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy
title_short Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy
title_sort predicting the effect of surface waviness on fatigue life of a wire + arc additive manufactured ti-6al-4v alloy
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10419546/
https://www.ncbi.nlm.nih.gov/pubmed/37570059
http://dx.doi.org/10.3390/ma16155355
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