Fatigue crack initiation and propagation in plain and notched PBF-LB/M, WAAM, and wrought 316L stainless steel specimens

Research output: Journal contributionsJournal articlesResearchpeer-review

Authors

  • Moritz Braun
  • Ting Chen
  • Junjun Shen
  • Henrik Fassmer
  • Benjamin Klusemann
  • Shahram Sheikhi
  • Sören Ehlers
  • Eckehard Müller
  • Ardeshir Sarmast
  • Jan Schubnell

Additively manufactured (AM) components—either made by laser-powder bed fusion or wire and arc additive manufacturing—typically contain process-related defects on and near surfaces that can be removed by machining. Various studies have shown that post-treatment, such as machining significantly improves the fatigue strength of AM parts. To this day, however, hardly any studies have investigated the fatigue strength of post-treated additively manufactured components with notches. In this study, fatigue tests were performed on plain and notched specimens to determine and compare the crack initiation and crack propagation behavior due to different manufacturing-related effects. Tests were performed on specimens produced by the two aforementioned AM processes and compared to specimens taken from wrought sheets. The fatigue strength of AM materials is influenced by microstructure, defects, residual stress, and notches. PBF-LB/M specimens exhibit the highest fatigue strength in plain, notch-free conditions, attributed to differences in microstructure and static strength affecting fatigue crack initiation. Notched specimens show larger differences among materials, with PBF-LB/M having shorter fatigue crack propagation life related to line-type defect clusters, while the plain PBF-LB/M specimens are less affected as their fatigue strength is primarily determined by fatigue crack initiation.

Original languageEnglish
Article number113122
JournalMaterials and Design
Volume244
Number of pages18
ISSN0264-1275
DOIs
Publication statusPublished - 08.2024

Bibliographical note

Publisher Copyright:
© 2024 The Author(s)

    Research areas

  • Fatigue strength assessment, Hybrid additive manufacturing, Microstructural defects, Post-production treatment, Selective laser melting, Wire arc additive manufacturing
  • Engineering