Tailoring the theory of critical distances to better assess the combined effect of complex geometries and process-inherent defects during the fatigue assessment of SLM Ti-6Al-4V

• DOI: 10.1016/j.ijfatigue.2023.107602
• Publication Date: 2023-03-11T11:05:21Z
• Authors: Bobby Gillham; Andrei Yankin; Fionnan McNamara; Charles Tomonto; Chunjie Huang; Jeroen Soete; Garret O'Donnell; Daniel Trimble; Shuo Yin; David Taylor; Rocco Lupoi
• Keywords: Selective Laser Melting

This work aims to apply the Theory of Critical Distances (TCD) fatigue assessment additively manufactured (AM) Ti-6Al-4V material produced via selective laser melting (SLM) process. Modified alternatives traditional TCD methods are considered. In this sense, it is sought develop a prediction model that better suited assessing impact multiple stress-rising features which located in close proximity each other. Hereby, consideration has been given modelling process-inherent surface roughness combination with an internally positioned artificial defect, shaped as feature reminiscent pore. Simultaneously, research also seeks circumnavigate potential issue respect current methodology. concerns matter applying practices components whereby area interest for conducting stress-distance analytics on size scale smaller than critical distance length parameter itself. Several different strategies were attempted way try and achieve meaningful modifications Results show possible overcome such challenges can often present themselves during appraisal AM metal parts. optimal novel strategy was experimented returned average error margins 13.7% or better. It anticipated models may assist further optimising accuracy service life evaluation metallic intended industry.