Fatigue of Ti6Al4V manufactured by PBF-LB: A comparison of failure mechanisms between net-shape and electro-chemically milled surface conditions

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL Engineering Failure Analysis Pub Date : 2025-05-01 Epub Date: 2025-02-14 DOI:10.1016/j.engfailanal.2025.109403

Tatiana Risposi , Lorenzo Rusnati , Luca Patriarca , Alex Hardaker , Dawid Luczyniec , Stefano Beretta

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Abstract

In the recent years, metal additive manufacturing (AM) has acquired large interest for many industrial applications, principally due to the capability to produce parts with complex geometry. The critical aspect of AM parts is the sensitivity to surface anomalies due to net-shape surfaces, i.e surface microcracks and protrusions, localized stresses caused by coarse surface roughness, or sub-surface features placed below the outer skin in the contour region. To reduce the surface roughness and increase the fatigue properties, proper post-process treatments can be applied. This work investigates the improvement in surface quality and fatigue properties due to the electro-chemical milling process of Hirtisation® compared with net-shape condition, on samples manufactured in Ti6Al4V by laser-powder bed fusion (PBF-LB). Post-processing led to a reduction of surface roughness due to the removal of the peaks and sharp valleys that act as crack initiation sites during fatigue tests, but it exposed the sub-skin contouring defects to the free surface. These were the crack initiation sites resulting in a limited improvement of the potential benefits produced by Hirtisation®. This was confirmed by fatigue life predictions based on propagation of surface features and contouring anomalies.

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PBF-LB法制备Ti6Al4V的疲劳：净形表面和电化学铣削表面失效机理的比较

近年来，金属增材制造（AM）在许多工业应用中获得了很大的兴趣，主要是因为它能够生产具有复杂几何形状的零件。增材制造零件的关键方面是对由于净形状表面引起的表面异常的敏感性，即表面微裂纹和突出，由粗糙表面粗糙度引起的局部应力，或位于轮廓区域外皮以下的次表面特征。为了降低表面粗糙度和提高疲劳性能，可以采用适当的后处理。本工作研究了Hirtisation®电化学铣削工艺对Ti6Al4V激光粉末床熔合（PBF-LB）样品表面质量和疲劳性能的改善，与净形状条件相比。后处理导致表面粗糙度的降低，因为在疲劳试验中去除了作为裂纹起始点的峰值和锐谷，但它将皮下轮廓缺陷暴露在自由表面。这些是导致Hirtisation®产生的潜在效益有限改善的裂缝起裂部位。基于表面特征传播和轮廓异常的疲劳寿命预测证实了这一点。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.