Fatigue crack growth mechanisms at the microstructure scale in as-fabricated and heat treated Ti-6Al-4V ELI manufactured by electron beam melting (EBM)

Galarraga, Haize; Warren, Robert J.; Lados, Diana A.; Dehoff, Ryan R.; Kirka, Michael M.

doi:10.1016/j.engfracmech.2017.03.024

Title: Fatigue crack growth mechanisms at the microstructure scale in as-fabricated and heat treated Ti-6Al-4V ELI manufactured by electron beam melting (EBM)

Journal Article · Mon Mar 20 00:00:00 EDT 2017 · Engineering Fracture Mechanics

DOI:https://doi.org/10.1016/j.engfracmech.2017.03.024· OSTI ID:1394298

Galarraga, Haize ^[1]; Warren, Robert J. ^[1]; Lados, Diana A. ^[1];

^[2];

^[2]

Worcester Polytechnic Inst., Worcester, MA (United States). Integrative Materials Design Center
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science & Technology Division; Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility

Electron beam melting (EBM) is a metal powder bed fusion additive manufacturing (AM) technology that fabricates parts by selectively scanning consecutive powder layers with an electron beam. Additive manufacturing technologies are increasing in importance for aerospace and medical applications, where the demand for a fundamental understanding and predictability of static and dynamic material properties are high. Ti-6Al-4V is the most widely used and studied alloy for this technology, and is the focus of this work in its Extra Low Interstitial (ELI) variation. The layered manufacturing of metallic components by EBM creates a unique directional microstructure, and consequently, anisotropic properties. Microstructure evolution, and its influence on mechanical properties of the alloy in the as-fabricated condition, has been documented by various researchers. However, fatigue crack propagation and the effects of the directional structure have not been sufficiently studied, imposing a barrier for this technology’s potential extension to high-integrity applications. Here in this study, fatigue crack growth (FCG) both parallel and perpendicular to the build directions was studied for different stress ratios and crack growth stages. The interaction between the directional as-fabricated EBM microstructure and FCG was investigated and compared to that of the equiaxed β annealed microstructure obtained by annealing above the β transus temperature. Finally, the FCG threshold, ΔK_th, was analytically modeled for the two relative crack propagation directions at different stress ratios, and FCG microstructural mechanisms were established for all three regions of crack propagation.

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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:: 1394298

Alternate ID(s):: OSTI ID: 1396583

Journal Information:: Engineering Fracture Mechanics, Vol. 176, Issue C; ISSN 0013-7944

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 64 works

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Additive Manufacturing of Titanium Alloys by Electron Beam Melting: A Review Zhang, Lai-Chang; Liu, Yujing; Li, Shujun Advanced Engineering Materials, Vol. 20, Issue 5 https://doi.org/10.1002/adem.201700842	journal	December 2017
Microstructure simulations of Inconel 718 during selective laser melting using a phase field model Wang, Xiaoqing; Chou, Kevin The International Journal of Advanced Manufacturing Technology, Vol. 100, Issue 9-12 https://doi.org/10.1007/s00170-018-2814-z	journal	October 2018
A Review of the Fatigue Properties of Additively Manufactured Ti-6Al-4V Cao, Fei; Zhang, Tiantian; Ryder, Matthew A. JOM, Vol. 70, Issue 3 https://doi.org/10.1007/s11837-017-2728-5	journal	January 2018
Tensile behavior of Ti-6Al-4V alloy fabricated by selective laser melting: effects of microstructures and as-built surface quality Tao, Pan; Li, Huai-xue; Huang, Bai-ying China Foundry, Vol. 15, Issue 4 https://doi.org/10.1007/s41230-018-8064-8	journal	July 2018
Influence of Inherent Surface and Internal Defects on Mechanical Properties of Additively Manufactured Ti6Al4V Alloy: Comparison between Selective Laser Melting and Electron Beam Melting Fousová, Michaela; Vojtěch, Dalibor; Doubrava, Karel Materials, Vol. 11, Issue 4 https://doi.org/10.3390/ma11040537	journal	March 2018
A Review of the As-Built SLM Ti-6Al-4V Mechanical Properties towards Achieving Fatigue Resistant Designs Agius, Dylan; Kourousis, Kyriakos; Wallbrink, Chris Metals, Vol. 8, Issue 1 https://doi.org/10.3390/met8010075	journal	January 2018

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