Fatigue Behavior of Additively-Manufactured Parts

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 4335

Special Issue Editor


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Guest Editor
Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia
Interests: My research is generally concerned with the investigation of fundamental industrial problems related to the processing, microstructure, and behavior of materials, ranging from metals to (nano-)composites for advanced structural and biomedical applications. My research focuses on scalable materials processing, including additive manufacturing and powder metallurgy, mechanical behavior at multiple length scales, bulk nanostructured alloys and composites, engineering biomaterials, and surface engineering.

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) has gained a lot of attention from both industry and academia. The combination of unique materials and incremental manufacturing in this technology provides opportunities for three-dimensionally structured parts with complex configurations and unique microstructures. However, while AM materials are emerging, their use is limited by the reliability of their mechanical properties, especially due to the fatigue behavior, due to the inherent process-induced imperfections (e.g., microporosity, high residual stresses, and large surface roughness). Indeed, a fairly high scatter in the fatigue strength of AM parts is commonly observed, which is attributed to the defects-induced stress concentration factors, which promote crack initiation at various locations. All of these necessitate further research in this area in order to increase the practicality of adopting AM in high-tech industrial applications.

Several important questions relating to the fatigue behavior of AM remain unexplored, notably the influence of building orientation and processing parameter, heat treatment, microstructural features for process-induced effects and the corresponding influence on quasistatic and fatigue properties, as well as understanding the damage and fracture mechanisms during cyclic loading.

In this Special Issue, we seek to provide a wide set of articles on current state-of-the-art research in fatigue behavior of additively-manufactured parts covering various materials systems that include metals and alloys, nanostructures, functionally gradient materials, porous materials, amorphous materials, shape memory alloys, high-entropy alloys, particle-reinforced metal/polymer matrix composites, and 3D tissues comprising multiple cell types. We welcome reviews and articles on the material design and process optimization, new assessment procedures and techniques, simulation methods, and experimental characterizations by integrating processing-microstructure-property relationships.

Dr. Bandar AlMangour
Guest Editor

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Keywords

  • Additive manufacturing
  • Fatigue strength
  • Cyclic deformation
  • Crack initiation and propagation
  • Strain energy density
  • Surface treatments
  • Design factors
  • Microstructure
  • Fractography
  • Optimization

Published Papers (1 paper)

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Research

17 pages, 4586 KiB  
Article
Effect of Thermomechanical Processing on Fatigue Behavior in Solid-State Additive Manufacturing of Al-Mg-Si Alloy
by Ben A. Rutherford, Dustin Z. Avery, Brandon J. Phillips, Harish M. Rao, Kevin J. Doherty, Paul G. Allison, Luke N. Brewer and J. Brian Jordon
Metals 2020, 10(7), 947; https://doi.org/10.3390/met10070947 - 14 Jul 2020
Cited by 51 | Viewed by 3922
Abstract
This work presents, for the first time, an in-depth investigation of the structure–property–fatigue relationships of an Al-Mg-Si alloy (AA6061) processed via additive friction stir-deposition (AFS-D). As industry focus continues to shift for more efficient and lightweight structures, quantitative studies on the cyclic performance [...] Read more.
This work presents, for the first time, an in-depth investigation of the structure–property–fatigue relationships of an Al-Mg-Si alloy (AA6061) processed via additive friction stir-deposition (AFS-D). As industry focus continues to shift for more efficient and lightweight structures, quantitative studies on the cyclic performance of additively manufactured materials are needed. In this study, the AFS-D processed AA6061-T6 was machined into specimens in two orthogonal orientations and subjected to monotonic and strain-controlled fatigue testing. The microstructural features of as-deposited AA6061 exhibited evidence of dynamic recrystallization and grain refinement. In addition, significant reduction in the intermetallic particles was observed after AFS-D processing. The fatigue results demonstrate that the as-deposited material, particularly the longitudinal direction, exhibited similar fatigue performance to wrought AA6061-T6 in both low-cycle and high-cycle fatigue regimes, which is a promising result for additively manufactured material in the as-deposited condition. By contrast, the as-deposited build direction orientation possessed slightly lower fatigue resistance than the wrought feedstock material. The AFS-D material was observed to exhibit different damage mechanisms from porosity-based damage mechanisms observed in fusion-based additively manufactured materials. Lastly, a microstructure-sensitive fatigue model was employed to capture the fatigue effects of the AFS-D processing on the AA6061. Full article
(This article belongs to the Special Issue Fatigue Behavior of Additively-Manufactured Parts)
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