Additive manufacturing of fatigue resistant materials: Challenges and opportunities

doi:10.1016/J.IJFATIGUE.2017.01.001

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Additive manufacturing of fatigue resistant materials: Challenges and opportunities

Journal Article•DOI•

Additive manufacturing of fatigue resistant materials: Challenges and opportunities

Aref Yadollahi¹, Nima Shamsaei²•Institutions (2)

Mississippi State University¹, Auburn University²

01 May 2017-International Journal of Fatigue (Elsevier)-Vol. 98, pp 14-31

TL;DR: In this article, the authors focus on the current state of knowledge pertaining to the mechanical characteristics of metallic parts fabricated via additive manufacturing (AM), as well as the ongoing challenges and imminent opportunities in fabricating materials with increased fatigue resistance.

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About: This article is published in International Journal of Fatigue.The article was published on 2017-05-01 and is currently open access. It has received 580 citations till now.

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Journal Article•DOI•

Additive manufacturing of metallic components – Process, structure and properties

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Tarasankar Debroy¹, Huiliang Wei¹, J.S. Zuback¹, T. Mukherjee¹, John W. Elmer², John O. Milewski, Allison M. Beese¹, Alexander E. Wilson-Heid¹, Amitava De³, Wei Zhang⁴ - Show less +6 more•Institutions (4)

Pennsylvania State University¹, Lawrence Livermore National Laboratory², Indian Institute of Technology Bombay³, Ohio State University⁴

01 Mar 2018-Progress in Materials Science

TL;DR: A review of the emerging research on additive manufacturing of metallic materials is provided in this article, which provides a comprehensive overview of the physical processes and the underlying science of metallurgical structure and properties of the deposited parts.

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4,192 citations

Cites background from "Additive manufacturing of fatigue r..."

...Yadollahi and Shamsaei identified additional challenges for determining fatigue properties of AMmaterials, including the variation in thermal histories from test coupons compared to complex in-service part geometries, which makes predicting full part performance based on the results of fatigue testing of simple coupons difficult [561]....
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...A review by Yadollahi and Shamsaei on the primary challenges for AM of increased fatigue resistant materials indicates that large, irregular voids, especially those near the surface, are the major life limiting factor for the fatigue lives of AM components [561]....
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Journal Article•DOI•

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting

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Nesma T. Aboulkhair¹, Marco Simonelli¹, Luke Parry¹, Ian Ashcroft¹, Christopher Tuck¹, Richard J.M. Hague¹ - Show less +2 more•Institutions (1)

University of Nottingham¹

01 Dec 2019-Progress in Materials Science

TL;DR: A comprehensive understanding of the interrelation between the various aspects of the subject, as this is essential to demonstrate credibility for industrial needs, is presented in this paper, which highlights some key topics requiring attention for further progression.

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761 citations

Journal Article•DOI•

Fatigue properties of AlSi10Mg obtained by additive manufacturing: Defect-based modelling and prediction of fatigue strength

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Simone Romano¹, Angelika Brückner-Foit², Ana D. Brandão³, Johannes Gumpinger³, T. Ghidini³, Stefano Beretta¹ - Show less +2 more•Institutions (3)

Polytechnic University of Milan¹, University of Kassel², European Space Research and Technology Centre³

01 Nov 2017-Engineering Fracture Mechanics

TL;DR: In this paper, a lower bound resistance curve was obtained, which introduced artificial defects of size corresponding to that of the largest occurring defects, and the same concepts were then applied in a fatigue crack growth simulation model based on the maximum defect size, for estimating both the life and scatter of the data in the region of elastic material response.

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294 citations

Journal Article•DOI•

3D printing for soft robotics - a review.

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Jahan Zeb Gul¹, Memoon Sajid¹, Muhammad Muqeet Rehman, Ghayas Uddin Siddiqui¹, Imran Shah¹, Kyung Hwan Kim¹, Jae-Wook Lee¹, Kyung Hyun Choi¹ - Show less +4 more•Institutions (1)

Jeju National University¹

08 Mar 2018-Science and Technology of Advanced Materials

TL;DR: The development of key 3D printing technologies and new materials along with composites for soft robotic applications is investigated and a brief summary of 3D-printed soft devices suitable for medical to industrial applications is included.

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260 citations

Journal Article•DOI•

Progress Towards Metal Additive Manufacturing Standardization to Support Qualification and Certification

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Mohsen Seifi¹, Michael Gorelik², Jess Waller, Nik Hrabe³, Nima Shamsaei⁴, Steve R. Daniewicz⁵, John J. Lewandowski¹ - Show less +3 more•Institutions (5)

Case Western Reserve University¹, Federal Aviation Administration², National Institute of Standards and Technology³, Auburn University⁴, University of Alabama⁵

16 Feb 2017-JOM

TL;DR: In this paper, the authors summarized some of the important standardization activities, as well as limitations associated with using currently available standards for metal AM with a focus on measuring mission-critical properties.

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Abstract: As the metal additive manufacturing (AM) industry moves towards industrial production, the need for qualification standards covering all aspects of the technology becomes ever more prevalent. While some standards and specifications for documenting the various aspects of AM processes and materials exist and continue to evolve, many such standards still need to be matured or are under consideration/development within standards development organizations. An important subset of this evolving the standardization domain has to do with critical property measurements for AM materials. While such measurement procedures are well documented, with various legacy standards for conventional metallic material forms such as cast or wrought structural alloys, many fewer standards are currently available to enable systematic evaluation of those properties in AM-processed metallic materials. This is due in part to the current lack of AM-specific standards and specifications for AM materials and processes, which are a logical precursor to the material characterization standards for any material system. This paper summarizes some of the important standardization activities, as well as limitations associated with using currently available standards for metal AM with a focus on measuring mission-critical properties. Technical considerations in support of future standards development, as well as a pathway for qualification/certification of AM parts enabled by the appropriate standardization landscape, are discussed.

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259 citations

Cites background from "Additive manufacturing of fatigue r..."

...AM processinduced defects can impact both low cycle fatigue (LCF) and high cycle fatigue (HCF) behavior [5], [9], [13], [32], [33] while also inducing significant scatter on fatigue properties, although some reports [29], [34] show improved performance with careful control of the process....
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...orientations [5], [32], [48], [49], [52]....
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...(b) The layer orientation may also affect the mechanical performance of AM parts and cause anisotropic behavior in monotonic and cyclic/fatigue properties [2], [5], [32], [47]–[51]....
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...), part geometry and/or the number of fabricated parts per build [5], [32]....
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...Special requirements of AM specimens, including surface quality, post-build machining, size, geometry, and build orientation should be addressed in such standards [5], [30], [32], [68], [70]–[75]....
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References

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Journal Article•DOI•

Metal Additive Manufacturing: A Review

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William E. Frazier¹•Institutions (1)

Naval Air Systems Command¹

08 Apr 2014-Journal of Materials Engineering and Performance

TL;DR: The state-of-the-art of additive manufacturing (AM) can be classified into three categories: direct digital manufacturing, free-form fabrication, or 3D printing as discussed by the authors.

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Abstract: This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.

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4,055 citations

"Additive manufacturing of fatigue r..." refers background in this paper

...The surface roughness of an AM part can be affected by the type of equipment, powder size, utilized process parameters, and its build orientation [4]....
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...This is primarily due to the fact that AM parts experience relatively high cooling rates during their fabrication, resulting in finer microstructure as compared to their conventionally-fabricated counterparts [4,9,15,16]....
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...as the build rate increases, surface quality decreases [4]....
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...In general, the surface roughness of AM parts typically increases by an increase in hatching pitch, layer thickness, or powder size [4]....
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...The main challenge against the continued adoption of AM by industries is the uncertainty in structural properties of their fabricated parts [3,4,9]....
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Book•

Metal fatigue in engineering

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R. I. Stephens, H. O. Fuchs

01 Jan 1980

TL;DR: In this paper, the authors present methods proven successful in practice, such as safe-life, fail-safe, forecasting of service reliability, monitoring, and inspection; macroscopic and microscopic aspects of fatigue behavior; principles for determining fatigue crack growth and final fracture; scatter of data and statistical methods; environmental factors; and fatigue of joints and compounds.

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Abstract: Presents methods proven successful in practice. Covers design procedures, such as safe-life, fail-safe, forecasting of service reliability, monitoring, and inspection; macroscopic and microscopic aspects of fatigue behavior; principles for determining fatigue crack growth and final fracture; scatter of data and statistical methods; environmental factors; and fatigue of joints and compounds. Contains design do's and don'ts and example problems.

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1,837 citations

"Additive manufacturing of fatigue r..." refers background in this paper

...Contrary to failures that occur under static loading, failure by fatigue is mostly a local phenomenon driven by impurities and microstructural heterogeneity – traits descriptive of metallic parts fabricated using current AM technology [9,11,17]....
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...It is well established that the surface roughness of parts can adversely affect its fatigue behavior [17]....
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...Since the crack initiation stage dominates the total fatigue lifetime in HCF, sensitivity to defects is more pronounced when compared to the low cycle fatigue (LCF) regime, where the crack propagation stage typically dominates the total fatigue lifetime [17]....
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...The more ductile behaving materials are typically less sensitive to impurities, as such materials are accommodating to an increased stress field around their voids through a larger local plastic zone [11,17]....
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...Typically, coarser grains can provide better crack growth resistance due to their larger grain boundaries, causing larger crack deflections [17,45,56]....
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Journal Article•DOI•

A critical plane approach to multiaxial fatigue damage including out-of-phase loading

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Ali Fatemi¹, Darrell F. Socie²•Institutions (2)

University of Toledo¹, University of Illinois at Urbana–Champaign²

01 Mar 1988-Fatigue & Fracture of Engineering Materials & Structures

TL;DR: In this paper, a modification to Brown and Miller's critical plane approach is proposed to predict multiaxial fatigue life under both in-phase and out-of-phase loading conditions.

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Abstract: — A modification to Brown and Miller's critical plane approach is proposed to predict multiaxial fatigue life under both in-phase and out-of-phase loading conditions. The components of this modified parameter consist of the maximum shear strain amplitude and the maximum normal stress on the maximum shear strain amplitude plane. Additional cyclic hardening developed during out-of-phase loading is included in the normal stress term. Also, the mathematical formulation of this new parameter is such that variable amplitude loading can be accommodated. Experimental results from tubular specimens made of 1045 HR steel under in-phase and 90° out-of-phase axial-torsional straining using both sinusoidal and trapezoidal wave forms were correlated within a factor of about two employing this approach. Available Inconel 718 axial-torsional data including mean strain histories were also satisfactorily correlated using the aforementioned parameter.

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1,493 citations

"Additive manufacturing of fatigue r..." refers methods in this paper

...The Fatemi-Socie (FS) model [81] is an example of a critical plane approach for shear damage materials, as presented by Eq....
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Journal Article•DOI•

Rapid manufacturing and rapid tooling with layer manufacturing (lm) technologies, state of the art and future perspectives

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Gideon Levy¹, Ralf Schindel¹, Jean-Pierre Kruth²•Institutions (2)

University of St. Gallen¹, The Catholic University of America²

01 Jan 2003-CIRP Annals

TL;DR: In this article, a systematic material dependent classification of layer manufacturing and process oriented metal part manufacturing techniques are proposed, mainly for metallic parts, polymer parts and tooling, and the generic and the major specific process characteristics and materials are described.

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1,080 citations

Journal Article•DOI•

On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: Fatigue resistance and crack growth performance

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Stefan Leuders¹, M. Thöne¹, Andre Riemer¹, Thomas Niendorf¹, Thomas Tröster¹, Hans Albert Richard¹, Hans Jürgen Maier¹ - Show less +3 more•Institutions (1)

University of Paderborn¹

01 Mar 2013-International Journal of Fatigue

TL;DR: In this article, the microstructure-defect-property relationship under cyclic loading for a TiAl6V4 alloy processed by selective laser melting is investigated. And the results show that the micron sized pores mainly affect fatigue strength, while residual stresses have a strong impact on fatigue crack growth.

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1,079 citations

"Additive manufacturing of fatigue r..." refers background in this paper

...Several studies have shown that employing HIP on AM Ti-6Al-4V can significantly improve its fatigue resistance, resulting in comparable fatigue strength relative to their wrought counterparts [24,30,31]....
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...pressure, temperature, and time), closure of a void is dependent on the encapsulated gas inside of it [30]....
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...The complete suppression of process-sourced voids in AM parts fabricated in an inert atmosphere may be difficult to achieve given the low solubility of common inert gases in the metal matrix [30,33]....
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