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Defects in Electron Beam Melted Ti-6Al-4V: Fatigue Life Prediction Using Experimental Data and Extreme Value
Viktor Sandell1, Thomas Hansson2, Sushovan Roychowdhury3
1Division of Materials Science, Luleå University of Technology, 731 87 Luleå, Sweden.
Materials (Basel, Switzerland)
|February 12, 2021
Summary
This study enhances the reliability of electron beam melting (EBM) for titanium alloys by using X-ray computed tomography (XCT) data to predict fatigue performance, enabling safer use in critical applications.
Area of Science:
- Materials Science
- Mechanical Engineering
- Additive Manufacturing
Background:
- Electron beam melting (EBM) is an additive manufacturing (AM) technique with design freedom but suffers from material defects.
- These defects cause variable fatigue performance, limiting EBM use for critical components.
Purpose of the Study:
- To compare fatigue test data with probabilistic fatigue life models for EBM Ti-6Al-4V.
- To assess the feasibility of using X-ray computed tomography (XCT) data for model input.
Main Methods:
- Fatigue testing of machined EBM Ti-6Al-4V specimens.
- Probabilistic fatigue life modeling using extreme value statistics on XCT data.
- Comparison with deterministic fatigue crack growth calculations.
Main Results:
- The probabilistic model accurately predicts fatigue life scatter bands and provides conservative life estimates.
- XCT data is a feasible input for the model, requiring minimal material volume for calibration.
Conclusions:
- Probabilistic modeling with XCT data improves the predictability of EBM Ti-6Al-4V fatigue performance.
- This approach supports the wider application of EBM for fatigue-critical parts.
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