Impact of defects on high cycle fatigue life in wire-arc additive manufactured TC17 alloy

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL Engineering Failure Analysis Pub Date : 2025-03-05 DOI:10.1016/j.engfailanal.2025.109480

Banglong Yu , Ping Wang , Peng Zhao , Xiaoguo Song , Man Jae SaGong , Hyoung Seop Kim

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Abstract

Engineering applications for additively manufactured (AM) titanium alloy components are often constrained by suboptimal fatigue properties and high variability in fatigue data due to defects. This study aims to address these limitations by developing a fatigue life prediction model that incorporates the influence of defects in wire arc additive manufacturing (WAAM) TC17 alloy. The microstructure and mechanical properties of WAAM-TC17 were thoroughly characterized. Results revealed that the average α-grains length and width in WAAM-TC17 was significantly smaller, approximately one-twelfth and one-seventeenth of that in Forged-TC17, respectively. The yield strength of the WAAM-TC17 horizontal and vertical specimens was approximately 93% of the Forged-TC17. However, the high-cycle fatigue (HCF) performance of WAAM-TC17 specimens was inferior due to crack initiation dominated by porosity and lack of fusion (LOF) defects. To enhance fatigue life prediction accuracy for defective WAAM-TC17 specimens, a novel parameter K*, derived from the stress concentration factor (K_t) using support vector regressor (SVR) in machine learning (ML), was introduced. The K*-N mean curve demonstrated high predictive accuracy for the HCF life of defective WAAM-TC17 specimens, with a standard deviation (STD) of 0.33.

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缺陷对线弧增材制造TC17合金高周疲劳寿命的影响

增材制造（AM）钛合金部件的工程应用常常受到次优疲劳性能和由缺陷引起的疲劳数据的高可变性的限制。本研究旨在通过开发包含电弧增材制造（WAAM） TC17合金中缺陷影响的疲劳寿命预测模型来解决这些局限性。对WAAM-TC17的显微组织和力学性能进行了全面表征。结果表明，WAAM-TC17的α-晶粒平均长度和宽度明显小于forge - tc17，分别约为其1 / 12和1 / 17。WAAM-TC17水平和垂直试样的屈服强度约为forge - tc17的93%。然而，WAAM-TC17试样的高周疲劳（HCF）性能较差，主要原因是裂纹萌生以孔隙率和LOF缺陷为主。为了提高缺陷WAAM-TC17试样的疲劳寿命预测精度，采用机器学习（ML）中的支持向量回归（SVR）方法，从应力集中系数（Kt）中导出了一个新的参数K*。K*-N均值曲线对WAAM-TC17缺陷试件的HCF寿命预测精度较高，标准差（STD）为0.33。

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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.