Fatigue‐life prediction of additively manufactured material: Effects of heat treatment and build orientation

In this study, the crack‐growth approach is used to predict the fatigue life of 17‐4 precipitation hardening (PH) stainless steel (SS) fabricated via an additive manufacturing (AM) system in different orientations (ie, vertical and horizontal) before and after heat treatment. To perform fatigue‐life...

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Bibliographic Details
Published in:Fatigue & fracture of engineering materials & structures 2020-04, Vol.43 (4), p.831-844
Main Authors: Yadollahi, Aref, Mahmoudi, Mohamad, Elwany, Alaa, Doude, Haley, Bian, Linkan, Newman, James C.
Format: Article
Language:English
Subjects:
Additive manufacturing
Crack closure
Crack propagation
crack‐growth
Defects
FASTRAN
Fatigue life
fatigue modelling
Heat treatment
laser powder bed fusion
Life prediction
Orientation effects
Precipitation hardening
Precipitation hardening steels
Stainless steels
Stress intensity factors
Vertical orientation
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Summary:In this study, the crack‐growth approach is used to predict the fatigue life of 17‐4 precipitation hardening (PH) stainless steel (SS) fabricated via an additive manufacturing (AM) system in different orientations (ie, vertical and horizontal) before and after heat treatment. To perform fatigue‐life calculations, the effective stress intensity factor as a function of crack‐growth rate was obtained from testing modified compact specimens with different crack orientations in as‐built and heat‐treated conditions. The plasticity‐induced crack closure model, FASTRAN, was used to calculate fatigue lives based on the size of process‐induced defects. Results indicated that in the presence of large voids (ie, lack‐of‐fusion defects), the total fatigue life of AM 17‐4 PH SS in as‐built and heat‐treated conditions is dominated by crack growth. Effect of build orientation on fatigue life of AM 17‐4 PH SS was also captured based on the size of defects projected on a plane perpendicular to the loading direction.
ISSN:8756-758X
1460-2695
DOI:10.1111/ffe.13200