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Title: 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:
 [1]; ORCiD logo [2];  [3]; ORCiD logo [2]; ORCiD logo [2];  [4];  [4]
  1. Univ. of Tennessee, Knoxville, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. Ohio Univ., Athens, OH (United States)
  4. 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), Advanced Manufacturing Office (EE-5A)
OSTI Identifier:
1564171
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. doi: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. doi: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 = {2018},
month = {9}
}

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