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Simulation of fatigue small crack growth in additive manufactured Ti–6Al–4V material

Gupta, A.; Sun, W.; Bennett, C. J.

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Authors

A. Gupta

W. Sun

CHRIS BENNETT C.Bennett@nottingham.ac.uk
Professor of Solid Mechanics



Contributors

Alok Gupta
Researcher

Wei Sun
Supervisor

Abstract

© 2020, The Author(s). Additive manufacturing (AM) offers design freedom and ability to fabricate parts of complex shapes which are not often possible with the conventional methods of manufacturing. In an AM part, even with optimum build parameters, a complete elimination of defects is not possible and this makes it hard to fully deploy the AM technology to build load bearing parts operating under cyclic loading conditions. Many of these defects are < 1mm in size and are categorised as ‘small cracks’. Local interaction of cracks with microstructural features and closure effects at the wake of the crack tip are some of the factors which make the growth behaviour of small and long cracks different. A crack growth life prediction method, which effectively considers the small crack growth behaviour, has been discussed in this paper. This proposed method includes a detailed finite element-based crack growth simulation using the ANSYS SMART fracture technology. The lifing calculations utilise the modified NASGRO equation and small crack growth data which was obtained from the published long crack growth data, corrected for closure effects. The predicted stress versus number of cycles curves were compared against the fatigue test results for the AM specimens in Ti–6Al–4V material. A good correlation between the predictions and test results suggests that the proposed method can be used to assess the small crack growth life of AM parts where the fatigue effects of cyclic loading can be quite significant.

Citation

Gupta, A., Sun, W., & Bennett, C. J. (2020). Simulation of fatigue small crack growth in additive manufactured Ti–6Al–4V material. Continuum Mechanics and Thermodynamics, 32, 1745–1761. https://doi.org/10.1007/s00161-020-00878-0

Journal Article Type Article
Acceptance Date Mar 5, 2020
Online Publication Date Mar 25, 2020
Publication Date 2020-11
Deposit Date Mar 6, 2020
Publicly Available Date Mar 29, 2024
Journal Continuum Mechanics and Thermodynamics
Print ISSN 0935-1175
Electronic ISSN 1432-0959
Publisher Springer Verlag
Peer Reviewed Peer Reviewed
Volume 32
Pages 1745–1761
DOI https://doi.org/10.1007/s00161-020-00878-0
Keywords Selective Laser Melting, Fatigue, Physically Small Cracks, Crack Growth, Defects, Ti-6Al-4V
Public URL https://nottingham-repository.worktribe.com/output/4097739
Publisher URL https://link.springer.com/article/10.1007/s00161-020-00878-0

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