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Metals
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Research on Fatigue Behavior of Additively Manufactured Materials
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Research on Fatigue Behavior of Additively Manufactured Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (31 May 2026) | Viewed by 4274

Editor

Dr. Fabio Scherillo

E-Mail Website
Guest Editor
Department of Chemical Engineering, Materials and Industrial Production, University of Naples Federico II, Napoli, Italy
Interests: manufacturing; metallurgy; additive manufacturing; fatigue; joining technologies; non conventional technologies; materials characterization
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The development of additive technologies in complex components represents a great innovation in recent years. However, additive technologies pose a series of problems for designers, particularly concerning components' durability. Studying the fatigue behavior of the materials used in additive technologies is necessary to obtain increasingly reliable components.

This issue aims to collect works in which the various aspects that influence the fatigue life of a component are studied, for example, the influence of process parameters, the type and concentration of defects, the surface quality, post-treatments, etc. Fractography studies are also important because they distinguish the different failure modes and support failure analysis.

Review and research articles, as are case studies, are welcome, particularly if linked to failure analysis.

Dr. Fabio Scherillo
Guest Editor

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 250 words) can be sent to the Editorial Office for assessment.

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-anonymized peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly 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 2600 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

  • fatigue
  • fracture
  • additive manufacturing
  • metals
  • polymers
  • surface
  • post-treatments
  • fractography

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Published Papers (3 papers)

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Research

14 pages, 4225 KB  
Article
Fatigue Behavior of Hybrid Additive/Subtractive Manufactured Ti-6Al-4V
by Nicholas Parolini, Andrew Ikeler, Ryan Kinser, Abhendra Singh, P. G. Allison and J. B. Jordon
Metals 2026, 16(6), 673; https://doi.org/10.3390/met16060673 - 18 Jun 2026
Viewed by 229
Abstract
Additive–subtractive hybrid manufacturing (ASHM) allows for the rapid manufacturing of metal components with complex and precise geometries for ready-to-use or near-ready-to-use applications. Laser wire-directed energy deposition (LW-DED) can be used to quickly manufacture metal components, while CNC machining can achieve precise geometric tolerances. [...] Read more.
Additive–subtractive hybrid manufacturing (ASHM) allows for the rapid manufacturing of metal components with complex and precise geometries for ready-to-use or near-ready-to-use applications. Laser wire-directed energy deposition (LW-DED) can be used to quickly manufacture metal components, while CNC machining can achieve precise geometric tolerances. In this study, Ti-6Al-4V alloy specimens were fabricated using an LW-DED process combined with CNC machining and tested to evaluate the effects of ASHM on mechanical performance. Post fabrication, the Ti-6Al-4V material was evaluated through hardness mapping, monotonic tensile testing, and fully reversed axial fatigue testing. Vicker’s micro-hardness mapping showed a range of hardness results from 300 to 350 HV in the ASHM Ti-6Al-4V that remained consistent throughout the build. Tensile results showed a similar response to cast and wrought Ti-6Al-4V, with an average yield stress of 819.4 MPa, ultimate tensile strength of 935.5 MPa, and modulus of 119 GPa. When tested in fatigue, the material had a reduced life compared to wrought Ti-6Al-4V, which is attributed to defects originating from the additive process. While no run-outs were observed from the testing, the fatigue results remain aligned with trends reported for other methods of additively manufactured Ti-6Al-4V. Fully reversed high-cycle fatigue loading revealed that the ASHM-fabricated Ti-6Al-4V fell into a Basquin power-law fit with a fatigue strength coefficient of 1942 MPa with a fatigue strength exponent of −0.115. The fatigue life of the ASHM material is found to be dependent on the resulting porosity of the material that stems from the LW-DED process used in the ASHM process described. Full article
(This article belongs to the Special Issue Research on Fatigue Behavior of Additively Manufactured Materials)
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16 pages, 8305 KB  
Article
Investigating Fracture Behavior in Titanium Aluminides: Surface Roughness as an Indicator of Fracture Mechanisms in Ti-48Al-2Cr-2Nb Alloys
by Alessia Serena Perna, Lorenzo Savio, Michele Coppola and Fabio Scherillo
Metals 2025, 15(1), 49; https://doi.org/10.3390/met15010049 - 7 Jan 2025
Cited by 3 | Viewed by 1584
Abstract
Titanium aluminides, particularly the Ti-48Al-2Cr-2Nb alloy, have drawn significant attention for their potential in high-temperature aerospace and automotive applications due to their exceptional performances and reduced density compared to nickel-based superalloys. However, their intermetallic nature poses challenges such as limited room-temperature ductility and [...] Read more.
Titanium aluminides, particularly the Ti-48Al-2Cr-2Nb alloy, have drawn significant attention for their potential in high-temperature aerospace and automotive applications due to their exceptional performances and reduced density compared to nickel-based superalloys. However, their intermetallic nature poses challenges such as limited room-temperature ductility and fracture toughness, limiting their widespread application. Additive manufacturing, specifically Electron Beam Melting (EBM), has emerged as a promising method for producing complex-shaped components of titanium aluminides, overcoming challenges associated with conventional production methods. This work investigates the fracture behavior of Ti-48Al-2Cr-2Nb specimens with different microstructures, including duplex and equiaxed, under tensile and high-cycle fatigue at elevated temperatures. Fracture surfaces were analyzed to distinguish between static and dynamic fracture modes. A novel method, employing confocal microscopy acquisitions, is proposed to correlate surface roughness parameters with the causes of failure, offering new insights into the fracture mechanisms of titanium aluminides. The results reveal significant differences in roughness values between the propagation and fracture zones for all the temperatures and microstructure tested. At 650 °C, the crack propagation zone exhibits lower Sq values than the fracture zone, with the fracture zone showing more pronounced roughness, particularly for the equiaxed microstructure. However, at 760 °C, the difference in Sq values between the propagation and fracture zones becomes more pronounced, with a more substantial increase in Sq values in the fracture zone. These findings contribute to understanding fracture behavior in titanium aluminides and provide a predictive framework for assessing structural integrity based on surface characteristics. Full article
(This article belongs to the Special Issue Research on Fatigue Behavior of Additively Manufactured Materials)
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16 pages, 4785 KB  
Article
The Determination of the Elastoplastic and Phase-Field Parameters for Monotonic and Fatigue Fracture of Sintered Steel Astaloy™ Mo+0.2C
by Tomislav Polančec, Tomislav Lesičar and Zdenko Tonković
Metals 2024, 14(10), 1138; https://doi.org/10.3390/met14101138 - 5 Oct 2024
Viewed by 1571
Abstract
This paper presents a procedure for determining the elastoplastic parameters of phase-field fracture of sintered material. The material considered was sintered steel Astaloy™ Mo+0.2C of three densities: 6.5, 6.8 and 7.1 g/cm3. The stress–strain curve and Wöhler curve, which are [...] Read more.
This paper presents a procedure for determining the elastoplastic parameters of phase-field fracture of sintered material. The material considered was sintered steel Astaloy™ Mo+0.2C of three densities: 6.5, 6.8 and 7.1 g/cm3. The stress–strain curve and Wöhler curve, which are experimentally obtained, are utilized for validation of the numerical simulations. For modelling of damage evolution, a CCPF (Convergence check phase-field) algorithm was used as a numerical framework. During calibration of the numerical parameters, two-dimensional as well as three-dimensional modelling was used. A comparison of different fatigue degradation functions known from the literature is also made. To improve the efficiency of numerical simulations of fatigue behaviour, the cycle skip technique is also employed. Full article
(This article belongs to the Special Issue Research on Fatigue Behavior of Additively Manufactured Materials)
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