Fatigue of Ti6Al4V Structural Health Monitoring Systems Produced by Selective Laser Melting

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• Selective Laser Melting (SLM) produces metallic components but faces challenges with residual stresses and fracture behavior.
• Titanium alloys are vital for aerospace and industrial applications due to their excellent mechanical properties.
• Structural Health Monitoring (SHM) is crucial for ensuring component integrity, with bionic engineering influencing new approaches like effective SHM (eSHM).

Purpose of the Study:

• To evaluate the functionality of Ti6Al4V produced by SLM within a novel eSHM system.
• To confirm the eSHM system's capability to detect cracks in SLM-manufactured components.
• To assess the impact of the integrated eSHM system on the fatigue crack initiation behavior of Ti6Al4V specimens.

Main Methods:

• Four-point bending fatigue tests were performed on Ti6Al4V specimens fabricated using SLM and equipped with an integrated eSHM system.
• Fractographic analysis was conducted post-failure to examine crack origins and propagation.
• Finite element simulations were employed to analyze stress distribution within the component and the integrated capillary network.

Main Results:

• The integrated eSHM system did not adversely affect the crack initiation behavior during fatigue testing.
• The eSHM system proved effective in detecting cracks within the SLM-produced Ti6Al4V components.
• Stress distribution analysis provided insights into the mechanical performance of the eSHM system within the component.

Conclusions:

• The eSHM system is a viable technology for monitoring the integrity of SLM-produced titanium alloy components.
• This integrated approach holds significant potential for enhancing safety and reliability in aerospace and industrial applications.
• The study confirms the successful application of eSHM in additive manufactured parts, paving the way for advanced structural monitoring.