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Article

A Numerical Study into the Effect of Machining on the Interaction between Surface Roughness and Surface Breaking Defects on the Durability of WAAM Ti-6Al-4V Parts

1
ARC Industrial Transformation Training Centre on Surface Engineering for Advanced Materials, School of Engineering, Swinburne University of Technology, John Street, Hawthorn, VIC 3122, Australia
2
Centre of Expertise for Structural Mechanics, Department of Mechanical and Aerospace Engineering, Monash University, Clayton, VIC 3800, Australia
3
US Army Research Laboratory, U.S. Army Combat Capabilities Development Command Weapons and Materials Research Directorate, Aberdeen Proving Ground, Aberdeen, MD 21005, USA
4
Solvus Global, 104 Prescott Street, Worcester, MA 01605, USA
*
Author to whom correspondence should be addressed.
Academic Editors: Yves Nadot, Jean-Yves Buffière, Franck Morel and Wei Zhou
Metals 2022, 12(7), 1121; https://doi.org/10.3390/met12071121
Received: 17 April 2022 / Revised: 25 June 2022 / Accepted: 27 June 2022 / Published: 29 June 2022
(This article belongs to the Special Issue Fatigue Behaviour of Additive Manufactured Metallic Materials)
The airworthiness certification of military aircraft requires a durability analysis be performed using linear elastic fracture mechanics (LEFM). Furthermore, such analyses need to use a valid small crack growth equation. This paper focuses on the effect of rough surfaces and the effect of machining the surface on the durability of AM parts using LEFM and a valid small crack growth equation for the material. To this end, this paper analyses the effect of surface roughness on wire and arc additively manufactured (WAAM) Ti-6Al-4V titanium parts and the effect of machining on the durability of a part. The analysis reveals that the life of the component is a relatively strong function of the degree of surface roughness, and that the durability of a specimen is a strong function of the local radius of the curvature of the trough. It also appears that surfaces with tall narrow roughness will not overly benefit from partial machining of the surface. View Full-Text
Keywords: additive manufacturing; surface roughness; fatigue life; durability additive manufacturing; surface roughness; fatigue life; durability
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MDPI and ACS Style

Peng, D.; Jones, R.; Ang, A.S.M.; Champagne, V.; Birt, A.; Michelson, A. A Numerical Study into the Effect of Machining on the Interaction between Surface Roughness and Surface Breaking Defects on the Durability of WAAM Ti-6Al-4V Parts. Metals 2022, 12, 1121. https://doi.org/10.3390/met12071121

AMA Style

Peng D, Jones R, Ang ASM, Champagne V, Birt A, Michelson A. A Numerical Study into the Effect of Machining on the Interaction between Surface Roughness and Surface Breaking Defects on the Durability of WAAM Ti-6Al-4V Parts. Metals. 2022; 12(7):1121. https://doi.org/10.3390/met12071121

Chicago/Turabian Style

Peng, Daren, Rhys Jones, Andrew S. M. Ang, Victor Champagne, Aaron Birt, and Alex Michelson. 2022. "A Numerical Study into the Effect of Machining on the Interaction between Surface Roughness and Surface Breaking Defects on the Durability of WAAM Ti-6Al-4V Parts" Metals 12, no. 7: 1121. https://doi.org/10.3390/met12071121

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