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Fatigue and Fracture Mechanics in Additive Manufacturing
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Fatigue and Fracture Mechanics in Additive Manufacturing

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 December 2024 | Viewed by 4776

Special Issue Editors

Dr. Aref Yadollahi

E-Mail Website
Guest Editor
Department of Mechanical and Civil Engineering, Purdue University Northwest, Hammond, IN 46323, USA
Interests: fatigue and fracture mechanics; metal additive manufacturing; structure-property relationships
Dr. Mohammad Mahtabi

E-Mail Website
Guest Editor
Department of Mechanical Engineering, The University of Tennessee at Chattanooga, Chattanooga, TN 37403, USA
Interests: additive manufacturing; fatigue and fracture mechanics; shape memory alloys; computational mechanics; mechanical behavior of materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Historically, meeting fatigue and durability certification requirements has proven to be challenging, especially for parts fabricated via novel manufacturing technologies such as additive manufacturing (AM). For highly regulated sectors, such as the aerospace and energy industries, the key challenge in the further adoption of metal AM is the qualification and certification of fabricated parts in applications whereby failure has major consequences. Thus, the fracture and fatigue-life assessment of metal AM parts is of major concern and must be addressed to fulfill the operational requirements and certification constraints for fatigue and fracture critical applications.

Fatigue strength and crack-propagation resistance are essential material properties for designing, optimizing, and managing the structural integrity of AM components. The major concern in the fatigue-life description of AM materials is the large degree of scatter in fatigue life and fatigue limit under similar loading conditions, mostly due to the presence of many process-induced defects and various kinds of heterogeneity (e.g., microstructure and residual stress). The development of robust and accurate models of damage formation, damage accumulation, and failure in AM materials demands accurate characterization of the material’s response to the combined effects of factors such as loading type, loading rate, and environmental conditions.

Research topics of interest include:

  • Structural integrity assessments of AM components;
  • Multi-scale, physics-based fatigue modeling of AM materials;
  • Computational fracture mechanics;
  • Fatigue and fracture of advanced AM materials;
  • High-temperature fatigue and fracture of AM materials;
  • Thermal–mechanical fatigue of AM materials;
  • Environmentally assisted crack growth in AM materials;
  • Residual stress effects on fatigue and fracture of AM materials;
  • Very high cycle fatigue (VHCF) of AM materials;
  • Multiaxial fatigue of AM materials.

Dr. Aref Yadollahi
Dr. Mohammad Mahtabi
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • crack nucleation
  • fatigue crack growth
  • small fatigue cracks
  • long crack thresholds
  • fatigue-life prediction
  • structural integrity
  • crack growth rate
  • damage formation
  • failure mechanism

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Published Papers (2 papers)

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Research

23 pages, 9665 KiB  
Article
Effects of Powder Reuse and Particle Size Distribution on Structural Integrity of Ti-6Al-4V Processed via Laser Beam Directed Energy Deposition
by MohammadBagher Mahtabi, Aref Yadollahi, Courtney Morgan-Barnes, Matthew W. Priddy and Hongjoo Rhee
J. Manuf. Mater. Process. 2024, 8(5), 209; https://doi.org/10.3390/jmmp8050209 - 25 Sep 2024
Viewed by 1528
Abstract
In metal additive manufacturing, reusing collected powder from previous builds is a standard practice driven by the substantial cost of metal powder. This approach not only reduces material expenses but also contributes to sustainability by minimizing waste. Despite its benefits, powder reuse introduces [...] Read more.
In metal additive manufacturing, reusing collected powder from previous builds is a standard practice driven by the substantial cost of metal powder. This approach not only reduces material expenses but also contributes to sustainability by minimizing waste. Despite its benefits, powder reuse introduces challenges related to maintaining the structural integrity of the components, making it a critical area of ongoing research and innovation. The reuse process can significantly alter powder characteristics, including flowability, size distribution, and chemical composition, subsequently affecting the microstructures and mechanical properties of the final components. Achieving repeatable and consistent printing outcomes requires powder particles to maintain specific and consistent physical and chemical properties. Variations in powder characteristics can lead to inconsistencies in the microstructural features of printed components and the formation of process-induced defects, compromising the quality and reliability of the final products. Thus, optimizing the powder recovery and reuse methodology is essential to ensure that cost reduction and sustainability benefits do not compromise product quality and reliability. This study investigated the impact of powder reuse and particle size distribution on the microstructural and mechanical properties of Ti-6Al-4V specimens fabricated using a laser beam directed energy deposition technique. Detailed evaluations were conducted on reused powders with two different size distributions, which were compared with their virgin counterparts. Microstructural features and process-induced defects were examined using scanning electron microscopy and X-ray computed tomography. The findings reveal significant alterations in the elemental composition of reused powder, with distinct trends observed for small and large particles. Additionally, powder reuse substantially influenced the formation of process-induced defects and, consequently, the fatigue performance of the components. Full article
(This article belongs to the Special Issue Fatigue and Fracture Mechanics in Additive Manufacturing)
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21 pages, 13234 KiB  
Article
Effect of Post-Processing Treatment on Fatigue Performance of Ti6Al4V Alloy Manufactured by Laser Powder Bed Fusion
by Ane Miren Mancisidor, María Belén García-Blanco, Iban Quintana, Pedro José Arrazola, Elixabete Espinosa, Mikel Cuesta, Joseba Albizuri and Fermin Garciandia
J. Manuf. Mater. Process. 2023, 7(4), 119; https://doi.org/10.3390/jmmp7040119 - 22 Jun 2023
Cited by 1 | Viewed by 1979
Abstract
Fatigue properties of parts are of particular concern for safety-critical structures. It is well-known that discontinuities in shape or non-uniformities in materials are frequently a potential nucleus of fatigue failure. This is especially crucial for the Ti6Al4V alloy, which presents high susceptibility to [...] Read more.
Fatigue properties of parts are of particular concern for safety-critical structures. It is well-known that discontinuities in shape or non-uniformities in materials are frequently a potential nucleus of fatigue failure. This is especially crucial for the Ti6Al4V alloy, which presents high susceptibility to the notch effect. This study investigates how post-processing treatments affect the mechanical performance of Ti6Al4V samples manufactured by laser powder bed fusion technology. All the fatigue samples were subjected to a HIP cycle and post-processed by machining and using combinations of alternative mechanical and electrochemical surface treatments. The relationship between surface properties such as roughness, topography and residual stresses with fatigue performance was assessed. Compressive residual stresses were introduced in all surface-treated samples, and after tribofinishing, roughness was reduced to 0.31 ± 0.10 µm, which was found to be the most critical factor. Fractures occurred on the surface as HIP removed critical internal defects. The irregularities found in the form of cavities or pits were stress concentrators that initiated cracks. It was concluded that machined surfaces presented a fatigue behavior comparable to wrought material, offering a fatigue limit superior to 450 MPa. Additionally, alternative surface treatments showed a fatigue behavior equivalent to the casting material. Full article
(This article belongs to the Special Issue Fatigue and Fracture Mechanics in Additive Manufacturing)
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