A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing
Abstract
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.
- Authors:
-
[2];
[2];
[2];
- 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)
- Publication Date:
- Research Org.:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Org.:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office
- OSTI Identifier:
- 1564171
- Alternate Identifier(s):
- OSTI ID: 1761216
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- International Journal of Fatigue
- Additional Journal Information:
- Journal Volume: 119; Journal Issue: C; Journal ID: ISSN 0142-1123
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Electron beam melting; Titanium; High cycle fatigue; S-N curves; Surface roughness; Fatigue crack initiation; Defects; Fatigue strength
Citation Formats
Chern, Andrew H., Nandwana, Peeyush, Yuan, Tao, Kirka, Michael M., Dehoff, Ryan R., Liaw, Peter K., and Duty, Chad E. A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing. United States: N. p., 2018.
Web. doi:10.1016/j.ijfatigue.2018.09.022.
Chern, Andrew H., Nandwana, Peeyush, Yuan, Tao, Kirka, Michael M., Dehoff, Ryan R., Liaw, Peter K., & Duty, Chad E. A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing. United States. https://doi.org/10.1016/j.ijfatigue.2018.09.022
Chern, Andrew H., Nandwana, Peeyush, Yuan, Tao, Kirka, Michael M., Dehoff, Ryan R., Liaw, Peter K., and Duty, Chad E. Mon .
"A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing". United States. https://doi.org/10.1016/j.ijfatigue.2018.09.022. https://www.osti.gov/servlets/purl/1564171.
@article{osti_1564171,
title = {A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing},
author = {Chern, Andrew H. and Nandwana, Peeyush and Yuan, Tao and Kirka, Michael M. and Dehoff, Ryan R. and Liaw, Peter K. and Duty, Chad E.},
abstractNote = {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.},
doi = {10.1016/j.ijfatigue.2018.09.022},
journal = {International Journal of Fatigue},
number = C,
volume = 119,
place = {United States},
year = {Mon Sep 24 00:00:00 EDT 2018},
month = {Mon Sep 24 00:00:00 EDT 2018}
}
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Figures / Tables:
Figure 1: Optical micrographs of EBM manufactured Ti-6Al-4V where (a) is an image of the x-y plane and (b) is an image of the z/build direction (used with permission).
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- The International Journal of Advanced Manufacturing Technology, Vol. 92, Issue 9-12
Powder bed charging during electron-beam additive manufacturing
journal, February 2017
- Cordero, Zachary C.; Meyer, Harry M.; Nandwana, Peeyush
- Acta Materialia, Vol. 124
Improving the fatigue performance of porous metallic biomaterials produced by Selective Laser Melting
journal, January 2017
- Van Hooreweder, Brecht; Apers, Yanni; Lietaert, Karel
- Acta Biomaterialia, Vol. 47
Application of mechanical surface finishing processes for roughness reduction and fatigue improvement of additively manufactured Ti-6Al-4V parts
journal, September 2017
- Bagehorn, S.; Wehr, J.; Maier, H. J.
- International Journal of Fatigue, Vol. 102
Surface Finishes for Ti-6Al-4V Alloy Produced by Direct Metal Laser Sintering
journal, August 2015
- Longhitano, Guilherme Arthur; Larosa, Maria Aparecida; Munhoz, André Luiz Jardini
- Materials Research, Vol. 18, Issue 4
Enhancement of Low-Cycle Fatigue Performance From Tailored Microstructures Enabled by Electron Beam Melting Additive Manufacturing Technology
journal, October 2015
- Morton, Philip A.; Mireles, Jorge; Mendoza, Heimdall
- Journal of Mechanical Design, Vol. 137, Issue 11
Site specific control of crystallographic grain orientation through electron beam additive manufacturing
journal, November 2014
- Dehoff, R. R.; Kirka, M. M.; Sames, W. J.
- Materials Science and Technology, Vol. 31, Issue 8
Fatigue life of additively manufactured Ti–6Al–4V in the very high cycle fatigue regime
journal, January 2017
- Günther, J.; Krewerth, D.; Lippmann, T.
- International Journal of Fatigue, Vol. 94
Microstructure and mechanical properties of Ti–6Al–4V manufactured by electron beam melting process
journal, December 2013
- Mohammadhosseini, A.; Fraser, D.; Masood, S. H.
- Materials Research Innovations, Vol. 17, Issue sup2
Works referencing / citing this record:
Fatigue Performance of Additively Manufactured Ti-6Al-4V: Surface Condition vs. Internal Defects
journal, January 2020
- Sun, Y. Y.; Lu, S. L.; Gulizia, S.
- JOM, Vol. 72, Issue 3
Laser Finishing of Ti6Al4V Additive Manufactured Parts by Electron Beam Melting
journal, December 2019
- Genna, Silvio; Rubino, Gianluca
- Applied Sciences, Vol. 10, Issue 1
Additive Manufacturing of High-Entropy Alloys: A Review
journal, December 2018
- Chen, Shuying; Tong, Yang; Liaw, Peter
- Entropy, Vol. 20, Issue 12
Surface Roughness Characterisation and Analysis of the Electron Beam Melting (EBM) Process
journal, July 2019
- Galati, Manuela; Minetola, Paolo; Rizza, Giovanni
- Materials, Vol. 12, Issue 13
Figures / Tables found in this record:
Figures/Tables have been extracted from DOE-funded journal article accepted manuscripts.