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Title: Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System

Abstract

Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the reference specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatlymore » reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored.« less

Authors:
 [1]; ORCiD logo [1];  [1]; ORCiD logo [1];  [1];  [1];  [1]
  1. Vrije Universiteit Brussel, Brussels (Belgium)
Publication Date:
Research Org.:
Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1415388
Report Number(s):
LA-UR-17-24400
Journal ID: ISSN 1996-1944; TRN: US1800789
Grant/Contract Number:  
AC52-06NA25396
Resource Type:
Accepted Manuscript
Journal Name:
Materials
Additional Journal Information:
Journal Volume: 10; Journal Issue: 9; Journal ID: ISSN 1996-1944
Publisher:
MDPI
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; structural health monitoring; fatigue; Ti-6Al-4V; additive manufacturing; 3D printing; laser metal deposition; directed energy deposition; eSHM

Citation Formats

Hinderdael, Michaël, Strantza, Maria, De Baere, Dieter, Devesse, Wim, De Graeve, Iris, Terryn, Herman, and Guillaume, Patrick. Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System. United States: N. p., 2017. Web. doi:10.3390/ma10090993.
Hinderdael, Michaël, Strantza, Maria, De Baere, Dieter, Devesse, Wim, De Graeve, Iris, Terryn, Herman, & Guillaume, Patrick. Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System. United States. https://doi.org/10.3390/ma10090993
Hinderdael, Michaël, Strantza, Maria, De Baere, Dieter, Devesse, Wim, De Graeve, Iris, Terryn, Herman, and Guillaume, Patrick. Fri . "Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System". United States. https://doi.org/10.3390/ma10090993. https://www.osti.gov/servlets/purl/1415388.
@article{osti_1415388,
title = {Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System},
author = {Hinderdael, Michaël and Strantza, Maria and De Baere, Dieter and Devesse, Wim and De Graeve, Iris and Terryn, Herman and Guillaume, Patrick},
abstractNote = {Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the reference specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatly reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored.},
doi = {10.3390/ma10090993},
journal = {Materials},
number = 9,
volume = 10,
place = {United States},
year = {Fri Aug 25 00:00:00 EDT 2017},
month = {Fri Aug 25 00:00:00 EDT 2017}
}

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Works referenced in this record:

Hardware-in-the-loop control of additive manufacturing processes using temperature feedback
journal, May 2016

  • Devesse, Wim; De Baere, Dieter; Hinderdael, Michaël
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Evaluation of SHM System Produced by Additive Manufacturing via Acoustic Emission and Other NDT Methods
journal, October 2015

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journal, March 2014


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journal, September 2013


Fatigue characterization of Titanium Ti-6Al-4V samples produced by Additive Manufacturing
journal, January 2016


Fatigue properties of a titanium alloy (Ti–6Al–4V) fabricated via electron beam melting (EBM): Effects of internal defects and residual stress
journal, January 2017


Hierarchical fiber-optic delamination detection system for carbon fiber reinforced plastic structures
journal, August 2012


Fatigue of Ti6Al4V Structural Health Monitoring Systems Produced by Selective Laser Melting
journal, February 2016

  • Strantza, Maria; Vafadari, Reza; de Baere, Dieter
  • Materials, Vol. 9, Issue 2
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Embedded 3D Printing of Strain Sensors within Highly Stretchable Elastomers
journal, June 2014

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Fatigue Performance of Laser Additive Manufactured Ti–6Al–4V in Very High Cycle Fatigue Regime up to 109 Cycles
journal, December 2015


Fatigue Behaviour of Additively Manufactured Ti-6Al-4V
journal, January 2015


Step loading for very high cycle fatigue
journal, September 2002


Staircase testing of a titanium alloy in the gigacycle regime
journal, November 2006


Electron Beam Additive Manufacturing of Titanium Components: Properties and Performance
journal, November 2013

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Design of a Model-based Controller with Temperature Feedback for Laser Cladding
journal, January 2014


Effect of microstructure and defects on fatigue behaviour of directed energy deposited Ti–6Al–4V
journal, June 2015


Feasibility study on integrated structural health monitoring system produced by metal three-dimensional printing
journal, September 2015

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  • DOI: 10.1177/1475921715604389

Validation of the step test method for generating Haigh diagrams for Ti–6Al–4V
journal, August 1999


Effect of surface roughness on fatigue performance of additive manufactured Ti–6Al–4V
journal, May 2015


Embedded 3D Printing of Strain Sensors within Highly Stretchable Elastomers
journal, June 2014

  • Muth, Joseph T.; Vogt, Daniel M.; Truby, Ryan L.
  • Advanced Materials, Vol. 26, Issue 36, p. 6307-6312
  • DOI: 10.1002/adma.201400334

Staircase testing of a titanium alloy in the gigacycle regime
journal, November 2006


Fatigue properties of a titanium alloy (Ti–6Al–4V) fabricated via electron beam melting (EBM): Effects of internal defects and residual stress
journal, January 2017


Fatigue performance evaluation of selective laser melted Ti–6Al–4V
journal, March 2014


Design of a Model-based Controller with Temperature Feedback for Laser Cladding
journal, January 2014


Fatigue Behaviour of Additively Manufactured Ti-6Al-4V
journal, January 2015


Fatigue characterization of Titanium Ti-6Al-4V samples produced by Additive Manufacturing
journal, January 2016


Progress in Additive Manufacturing and Rapid Prototyping
journal, January 1998


Step loading for very high cycle fatigue
journal, September 2002


Hierarchical fiber-optic delamination detection system for carbon fiber reinforced plastic structures
journal, August 2012


Electron Beam Additive Manufacturing of Titanium Components: Properties and Performance
journal, November 2013

  • Edwards, P.; O'Conner, A.; Ramulu, M.
  • Journal of Manufacturing Science and Engineering, Vol. 135, Issue 6
  • DOI: 10.1115/1.4025773

Fatigue Performance of Laser Additive Manufactured Ti–6al–4V in Very High Cycle Fatigue Regime up to 1E9 Cycles
text, January 2015

  • Wycisk, Eric; Siddique, Shafaqat; Herzog, Dirk
  • TUHH Universitätsbibliothek
  • DOI: 10.15480/882.1270

Hardware-in-the-loop control of additive manufacturing processes using temperature feedback
journal, May 2016

  • Devesse, Wim; De Baere, Dieter; Hinderdael, Michaël
  • Journal of Laser Applications, Vol. 28, Issue 2
  • DOI: 10.2351/1.4943911

Fatigue of Ti6Al4V Structural Health Monitoring Systems Produced by Selective Laser Melting
journal, February 2016

  • Strantza, Maria; Vafadari, Reza; de Baere, Dieter
  • Materials, Vol. 9, Issue 2
  • DOI: 10.3390/ma9020106

Works referencing / citing this record:

Fatigue failure monitoring of 316L stainless steel coupons using optical fibre based distributed strain sensing
journal, September 2019

  • De Pauw, Ben; Hinderdael, Michaël; Moonens, Marc
  • Smart Materials and Structures, Vol. 28, Issue 10
  • DOI: 10.1088/1361-665x/ab32cd

Fatigue Performance of Powder Bed Fused Ti-6Al-4V Component with Integrated Chemically Etched Capillary for Structural Health Monitoring Application
conference, June 2018

  • Hinderdael, Michaël F.; Baere, Dieter De; Guillaume, Patrick
  • The 18th International Conference on Experimental Mechanics
  • DOI: 10.3390/icem18-05419