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The safe fatigue design of metallic components fabricated by additive manufacturing (AM) is still a largely unsolved problem. This is primarily due to (a) a significant inhomogeneity of the material properties across the component; (b) defects such as porosity and lack of fusion as well as pronounced surface roughness of the asuilt components; and (c) residual stresses, which are very often present in the as‐built parts and need to be removed by post‐fabrication treatments. Such morphological and microstructural features are very different than in conventionally manufactured parts and play a much bigger role in determining the fatigue life. The above problems require specific solutions with respect to the identification of the critical (failure) sites in AM fabricated components. Moreover, the generation of representative test specimens characterized by similar temperature cycles needs to be guaranteed if one wants to reproducibly identify the critical sites and establish fatigue assessment methods taking into account the effect of defects on crack initiation and early propagation. The latter requires fracture mechanics‐based approaches which, unlike common methodologies, cover the specific characteristics of so‐called short fatigue cracks. This paper provides a discussion of all these aspects with special focus on components manufactured by laser powder bed fusion (L‐PBF). It shows how to adapt existing solutions, identifies fields where there are still gaps, and discusses proposals for potential improvement of the damage tolerance design of L‐PBF components
Components in aircrafts are usually replaced when critical defects are present.
An alternative approach is repairing using gas dynamic cold spraying: metal particles are shot at a surface at supersonic speeds to selectively rebuild damaged material. Compared to other material-deposition techniques, its advantage is the small thermal impact on the component, preserving its mechanical properties.
Component-repair can save considerable amounts of energy and resources. However, its industrial application at large scale needs reproducible, good repair-material properties to guarantee a safe component life. The aim of this project is the development of safe, automatized repair-procedures considering the mechanical fatigue properties of the repair.
The fatigue assessment of welded joints requires several input data, which can be subdivided into three categories: geometry, material and loading. The number of input data depends essentially on the complexity of the models employed and on the level of accuracy of the analysis. It is common practice to use safety factors in design to account for the scatter of the input parameters. Nevertheless, overly-conservative factors lead often to unrealistic estimations of fatigue life. This work presents a fracture mechanics-based model for the structural integrity assessment of welded joints under constant amplitude fatigue loading, in which the local geometry at the weld toe and the fatigue crack growth properties are considered statistically distributed. The approach is validated against a large number of experimental data.
Structural alloys are largely employed in key industrial sectors and their demand is predicted to rise rapidly for the next decades. Most of these materials require a large amount of energy for extraction and manufacturing, which causes the emission of greenhouse gases and other pollutants. Therefore, strategies for improving the sustainability of structural metallic alloys are urgently needed.
Additive Manufacturing (AM), in particular Laser Powder Bed Fusion (PBF-LB/M), aims to be a sustainable manufacturing process, as it allows the build-up of complex geometry in near net-shape from 3D models, while minimizing material waste and the energy required for the process and post-process treatments.
Nevertheless, the application of additively manufactured parts in structural safety-relevant applications is still hindered by the poor fatigue performance. The cause of this has been mainly attributed to the presence of manufacturing defects and surface roughness. Therefore, a huge effort has been made to optimize the process parameters and to introduce post-process treatments to minimize the defect content. However, material flaws cannot be fully eliminated, but these can be considered in a damage tolerance framework for the prediction of the fatigue performance of additively manufactured metallic materials, which is essential for part design and qualification.
This work aims at presenting different modelling strategies for the prediction of the fatigue limit of AM metals. Simple empirical models and more complex models based on fatigue short crack propagation are proposed. The investigated material is an AlSi10Mg alloy fabricated by PBF-LB/M and subjected to two different low-temperature heat-treatments (265°C for 1 h and 300°C for 2h). The results show that the models can provide good approximation of the fatigue limits and help in the interpretation of the scatter of fatigue data.
Optimized planning and evaluation of dental implant fatigue testing: A specific software application
(2020)
Mechanical complications in implant-supported fixed dental prostheses are often related to implant and prosthetic design. Although the current ISO 14801 provides a framework for the evaluation of dental implant mechanical reliability, strict adherence to it may be difficult to achieve due to the large number of test specimens which it requires as well as the fact that it does not offer any probabilistic reference for determining the endurance limit. In order to address these issues, a new software program called ProFatigue is presented as a potentially powerful tool to optimize fatigue testing of implant-supported prostheses. The present work provides a brief description of some concepts such as load, fatigue and stress-number of cycles to failure curves (S-N curves), before subsequently describing the current regulatory situation. After analyzing the two most recent versions of the ISO recommendation (from 2008 and 2016), some limitations inherent to the experimental methods which they propose are highlighted. Finally, the main advantages and instructions for the correct implementation of the ProFatigue free software are given. This software will contribute to improving the performance of fatigue testing in a more accurate and optimized way, helping researchers to gain a better understanding of the behavior of dental implants in this type of mechanical test.
Laser Powder Bed Fusion (L-PBF) allow the fabrication of lightweight near net shape AlSi10Mg components attractive to the aerospace, automotive, biomedical and military industries. During the build-up process, high cooling rates occur. Thus, L-PBF AlSi10Mg alloys exhibit a Si-nanostructure in the as-built condition, which leads to superior mechanical properties compared to conventional cast materials. At the same time, such high thermal gradients generally involve a deleterious residual stress (RS) state that needs to be assessed during the design process, before placing a component in service. To this purpose post-process heat treatments are commonly performed to relieve detrimental RS. In this contribution two low-temperature stress-relief heat treatments (SRHT) are studied and compared with the as-built state: a SRHT at 265°C for 1 hour and a SRHT at 300°C for 2 hours. At these temperatures microstructural changes occur. In the as-built state, Si atoms are supersaturated in the α-aluminium matrix, which is enveloped by a eutectic Si-network. At 265°C the Si precipitation from the matrix to the pre-existing network is triggered. Thereafter, above 295°C the fragmentation and spheroidization of the Si branches takes place, presumably by Al–Si interdiffusion. After 2 hours the original eutectic network is completely replaced by uniformly distributed blocky particles. The effect of the heat and the microstructure modification on the RS state and the fatigue properties is investigated. Energy dispersive x-ray and neutron diffraction are combined to investigate the near-surface and bulk RS state of a L-PBF AlSi10Mg material. Differences in the endurance limit are evaluated experimentally by high cycle fatigue (HCF) tests and cyclic R-curve determination.
Fatigue tests were performed on the forged aluminum alloy EN AW-2618A in the T61 state. Different stress ratios (R = -1, R = 0.1) were selected to study the influence of mean stress on fatigue life. Two overaged states (10 h/230 ◦C, 1000 h/230 ◦C) were also tested to investigate the influence of overaging on fatigue life. Transmission electron microscopy (TEM) was used to characterize the precipitates (S-phase), which are mainly responsible for the strength of the alloy. A fractographic analysis was also performed to determine the failure mode. Overaging reduces the fatigue life compared to the T61 state. The longer the aging time, the lower the fatigue resistance. The reason is the decrease in (yield) strength, which correlates with the radius of the S-phase: the precipitate radius increases by a factor of approximately two for the overaged states compared to the initial state. The analysis of the fracture surfaces showed crack initiation occurs predominantly on the outer surface and is
associated with the primary phases.
The process-structure-property-performance relationship is a fundamental paradigm in metal additive manufacturing (AM). The knowledge of how process parameters and post-process treatments influence the material properties and therefore the structural integrity of additively manufactured metallic components is of paramount importance. With respect to this, one of the unsolved problems related to the unique AM process is the reliability of witness samples for part qualification. Focusing on the Laser Powder Bed Fusion (PBF-LB/M) process, the microstructure and therefore the mechanical performance of test coupons are not representative of parts of the same material in every case. This work summarizes part of the results of an ongoing cooperation between BAM and BASF, which aims at addressing this issue by designing dedicated specimens, representative of the fatigue properties of the real component. The considered case study consisted in the fabrication and characterization of the fatigue properties of a pressure vessel made of AISI 316L. The first phase of the project was devoted to the process monitoring to understand the relationship between process parameters and temperature distribution during the fabrication of the component. Finite element models were tuned on the experimental data from the process monitoring and simulations of the temperature field in the component were conducted. The numerical results were in good agreement with the temperature profiles measured during the fabrication of the component. The second phase dealt with the evaluation of the fatigue and fatigue crack propagation properties on specimens extracted from different regions of the pressure vessel. The experimental investigations showed significant differences in hoop and longitudinal direction. A clear dependence of the fatigue properties on heat accumulation (temperature distribution) and defect size was pointed out. The third phase encompassed the fabrication and testing of the representative specimens. Numerical simulations were used to design specimens displaying the same temperature profile as in the most critical region of the component. The fatigue testing of the representative specimens is subject of ongoing work.
Additive manufacturing (AM) is becoming increasingly important in engineering applications due to the possibility of producing components with a high geometrical complexity allowing for optimized forms with respect to the in-service functionality. Despite the promising potential, AM components are still far from being used in safety-relevant applications, mainly due to a lack of understanding of the feedstock-process-properties-performance relationship. This work aims at providing a full characterization of the fatigue behavior of the additively manufactured AISI 316L austenitic stainless steel and a direct comparison with the fatigue performance of the wrought steel. To this purpose, a set of specimens has been produced by laser powder bed fusion (L-PBF) and subsequently heat treated at 900 °C for 1 hour for complete stress relief, whereas a second set of specimens has been machined out of hot-rolled plates. Low cycle fatigue (LCF) and high cycle fatigue (HCF) tests have been conducted for characterizing the fatigue behavior. The L-PBF material had a higher fatigue limit and better finite life performance compared to wrought material. Both, LCF and HCF-testing revealed an extensive cyclic softening.
Additively Manufactured (AM) parts are still far from being used in safety-relevant applications, mainly due to a lack of understanding of the feedstock-process-propertiesperformance relationship. This work aims at providing a characterization of the fatigue behavior of the additively manufactured AISI 316L austenitic stainless steel and a direct comparison with the fatigue performance of the wrought steel. A set of specimens has been produced by laser powder bed fusion (L-PBF) and a second set of specimens has been machined out of hot-rolled plates. The L-PBF material shows a higher fatigue limit and better finite life performance compared to the wrought material, accompanied by an extensive amount of cyclic softening.