The effects of microstructure and porosity on the competing fatigue failure mechanisms in powder metallurgy Ti-6Al-4V

Dunstan, Matthew K.; Paramore, James D.; Fang, Z. Zak

doi:10.1016/j.ijfatigue.2018.07.006

The effects of microstructure and porosity on the competing fatigue failure mechanisms in powder metallurgy Ti-6Al-4V

Journal Article · Thu Jul 19 00:00:00 EDT 2018 · International Journal of Fatigue

DOI:https://doi.org/10.1016/j.ijfatigue.2018.07.006· OSTI ID:1613308

Dunstan, Matthew K. ^[1]; Paramore, James D. ^[2]; Fang, Z. Zak ^[3]

Univ. of Utah, Salt Lake City, UT (United States); DOE/OSTI
Univ. of Utah, Salt Lake City, UT (United States); Army Research Lab., Adelphi, MD (United States)
Univ. of Utah, Salt Lake City, UT (United States)

In near-net-shape manufacturing methods, such as powder metallurgy, additive manufacturing, and metal injection molding, porosity has historically been viewed as the sole limiting factor for fatigue life. This is because pores tend to act as stress concentrators. However, in this work, a fractographic analysis of Ti-6Al-4V produced through several powder metallurgy techniques has shown that microstructural faceting due to slip can cause fatigue failure, even in the presence of porosity. The likelihood of pore related failure was found to be dependent on microstructure size and morphology. Further, a minimum pore size threshold was found to exist for each microstructure, under which pores will not cause fatigue failure. A simple model was developed to determine this threshold based on the microstructural characteristics of the material. This model was then compared to experimental data and properly predicted the fatigue failure mechanism in over 99% of the samples examined.

View Accepted Manuscript (DOE)

Research Organization:: University of Utah, Salt Lake City, UT (United States)

Sponsoring Organization:: USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0005761

OSTI ID:: 1613308

Alternate ID(s):: OSTI ID: 1693698

Journal Information:: International Journal of Fatigue, Journal Name: International Journal of Fatigue Journal Issue: C Vol. 116; ISSN 0142-1123

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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