The material of Ti–6Al–4V has been widely applied in various industries, such as automobile, aerospace, and medical due to its high specific strength, superior thermal stability and strong corrosion resistance. In the recent decades, selective laser melting (SLM) has become an attractive method to fabricate Ti–6Al–4V parts, thanks to its significant advantages in low material consumption, the high degree of freedom in design, low carbon footprint, etc. Predictability of SLM material fatigue properties is especially important for the safety-critical structures under dynamic load cases. The present research is aimed at evaluating the low cycle fatigue (LCF) performance of SLM Ti–6Al–4V under high loading states. LCF tests were performed for as-built and annealed SLM Ti–6Al–4V. Comparison between LCF properties of SLM Ti–6Al–4V and the wrought Ti–6Al–4V was also made. It was found that as-built SLM Ti–6Al–4V demonstrated a comparable LCF performance with the wrought material. The LCF life of as-built SLM Ti–6Al–4V was longer than that of wrought Ti–6Al–4V at lower strain amplitudes. However, the wrought Ti–6Al–4V had better LCF performance at higher strain amplitudes. The results revealed that the porosity in the as-built SLM material exerted much more impact on the degradation of the material at high strain amplitudes. Annealing deteriorated the LCF performance of SLM Ti–6Al–4V material due to the formation of coarser grains. The cyclic Ramberg–Osgood and the Basquin–Coffin–Manson models were fitted to depict the cyclic stress–strain and the strain–life curves for the SLM Ti–6Al–4V, based on which the LCF performance parameters were determined. In addition, the fatigue fracture surfaces were observed by using scanning electron microscopy (SEM), and the results indicated that fatigue cracks originated from the surface or subsurface defects.
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