A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing

Chern, Andrew H.; Nandwana, Peeyush; Yuan, Tao; Kirka, Michael M.; Dehoff, Ryan R.; Liaw, Peter K.; Duty, Chad E.

doi:10.1016/j.ijfatigue.2018.09.022

Title: A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing

Journal Article · 24 September 2018 · International Journal of Fatigue

DOI: https://doi.org/10.1016/j.ijfatigue.2018.09.022 · OSTI ID:1564171

Chern, Andrew H. ^[1];

^[2]; Yuan, Tao ^[3];

^[2];

^[2]; Liaw, Peter K. ^[4]; Duty, Chad E. ^[4]

Univ. of Tennessee, Knoxville, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Ohio Univ., Athens, OH (United States)
Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Electron beam melting (EBM) is a swiftyly-developing metal additive manufacturing process that holds significant interest in the aerospace and biomedical industries for the high-strength titanium alloy, Ti-6Al-4V. These industries have fatigue-limited applications, yet a lack of understanding of the EBM process-microstructure-fatigue relationships limit widespread use and presents challenges for certification. In this review, uniaxial fatigue data was collected and the effects of build orientation, surface roughness, and hot-isostatic pressing are linked to the fatigue properties highlighting microstructure, defects, and failure mechanisms. The observations and conclusions are supported by statistical analysis using the mean fatigue life obtained by the Statistical Fatigue-Limit Model. Both EBM-process and post-process structure relationships are discussed in order to identify the best-practice for fatigue-resistant design. The performance of the EBM material is compared to conventionally manufactured Ti-6Al-4V and possible methods to increase the fatigue resistance are discussed. Anisotropic fatigue behavior was observed in as-fabricated parts and no statistical distinction was found in the fatigue performance of HIPed and as-fabricated material provided the same as-fabricated rough surface condition. However, comparable fatigue life to traditionally manufactured lamellar Ti-6Al-4V is achieved when both post-process HIP and machining are applied to EBM-fabricated parts.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1564171

Alternate ID(s):: OSTI ID: 1761216

Journal Information:: International Journal of Fatigue, Vol. 119, Issue C; ISSN 0142-1123

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 119 works

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