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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| Format: | Article |
| Language: | English |
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MDPI AG
2023-07-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/15/5355 |
| _version_ | 1797586436539547648 |
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| author | Muhammad Shamir Xiang Zhang Abdul Khadar Syed Wayne Sadler |
| author_facet | Muhammad Shamir Xiang Zhang Abdul Khadar Syed Wayne Sadler |
| author_sort | Muhammad Shamir |
| collection | DOAJ |
| 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. |
| first_indexed | 2024-03-11T00:23:12Z |
| format | Article |
| id | doaj.art-310e545d93c245a593a5fa92735716c2 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T00:23:12Z |
| publishDate | 2023-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-310e545d93c245a593a5fa92735716c22023-11-18T23:12:13ZengMDPI AGMaterials1996-19442023-07-011615535510.3390/ma16155355Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V AlloyMuhammad Shamir0Xiang Zhang1Abdul Khadar Syed2Wayne Sadler3Centre for Manufacturing and Materials, Coventry University, Coventry CV1 5FB, UKCentre for Manufacturing and Materials, Coventry University, Coventry CV1 5FB, UKCentre for Manufacturing and Materials, Coventry University, Coventry CV1 5FB, UKCentre for Manufacturing and Materials, Coventry University, Coventry CV1 5FB, UKThis 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.https://www.mdpi.com/1996-1944/16/15/5355WAAMsurface wavinesssurface roughnessfatiguebending testdurability |
| spellingShingle | Muhammad Shamir Xiang Zhang Abdul Khadar Syed Wayne Sadler Predicting the Effect of Surface Waviness on Fatigue Life of a Wire + Arc Additive Manufactured Ti-6Al-4V Alloy Materials WAAM surface waviness surface roughness fatigue bending test durability |
| 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 | WAAM surface waviness surface roughness fatigue bending test durability |
| url | https://www.mdpi.com/1996-1944/16/15/5355 |
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