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Fatigue Strength and Mechanical Properties of Conventional and Additive Manufactured Alloys

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: closed (20 January 2024) | Viewed by 3488

Special Issue Editors


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Guest Editor
Department of Mechanical and Industrial Engineering, Norwegian University of Science and Technology, 7491 Trondheim, Norway
Interests: fatigue and fracture; fracture mechanics; multiaxial fatigue; additive manufacturing; fatigue life assessment methodologies; local approaches

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Guest Editor
Department of Engineering, University of Messina, Contrada di Dio (S. Agata), 98166 Messina, Italy
Interests: tribology; wear; microstructure characterization
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Guest Editor
Department of Engineering, University of Messina, Contrada di Dio (S. Agata), 98166 Messina, Italy
Interests: biomaterials; mechanical engineering
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Department of Engineering, University of Messina, 98166 Messina, Italy
Interests: mechanical behavior of materials; mechanical testing; mechanics of materials; thermography; finite element analysis; infrared thermography; fatigue of materials; fatigue and fracture analysis
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) techniques have become widely acknowledged, allowing highly complex mechanical parts to be produced, which are not achievable with traditional manufacturing techniques. One of the major advantages of AM is the possibility to customize the shape and mechanical properties of the component, resulting in more application prospects, such as in aerospace, biomedical, and automotive industries. However, AM processes cause a high variability in the achieved mechanical properties that are closely related to the process parameters.

Indeed, depending on the process parameters, the component may be affected by poor surface quality and several defects (such as porosities, inclusions, and a lack of fusion defects). The microstructure is well affected due to the thermal history experienced by the component during the production process, leading to inhomogeneous and anisotropic features. All these aspects affect the mechanical properties of the final component.

Fatigue failure represents the most common in-service failure of mechanical components, and it is highly influenced by the presence of defects. Research efforts are needed both to improve the quality of the produced AM parts and to develop methodologies to directly account for all the factors that influence the fatigue behaviour. Such developments in the AM techniques and in the design methodologies are highly desirable to ensure a sufficient degree of reliability for AM parts and, as a consequence, to promote their use at an industrial scale.

This Special Issue aims to collect original studies on the fatigue characterization of AM alloys, presenting the experimental fatigue results in relation to process parameters and providing information on failure mechanisms and microstructural features and defects. Papers that compare the fatigue properties of AM and conventional alloys are highly appreciated, as well as those that focus on numerical techniques for fatigue life assessment.

Dr. Pietro Foti
Dr. Danilo D'Andrea
Dr. Dario Santonocito
Dr. Giacomo Risitano
Guest Editors

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Keywords

  • microstructure
  • defects
  • fatigue behaviour
  • failure mechanisms
  • mechanical properties
  • process parameters
  • additive manufacturing
  • fatigue life assessment

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Published Papers (2 papers)

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Research

13 pages, 4434 KiB  
Article
Effective Platform Heating for Laser Powder Bed Fusion of an Al-Mn-Sc-Based Alloy
by Dina Bayoumy, Torben Boll, Amal Shaji Karapuzha, Xinhua Wu, Yuman Zhu and Aijun Huang
Materials 2023, 16(24), 7586; https://doi.org/10.3390/ma16247586 - 10 Dec 2023
Cited by 3 | Viewed by 1390
Abstract
Platform heating is one of the effective strategies used in laser powder bed fusion (LPBF) to avoid cracking during manufacturing, especially when building relatively large-size components, as it removes significant process-induced residual strains. In this work, we propose a novel and simple method [...] Read more.
Platform heating is one of the effective strategies used in laser powder bed fusion (LPBF) to avoid cracking during manufacturing, especially when building relatively large-size components, as it removes significant process-induced residual strains. In this work, we propose a novel and simple method to spare the elaborate post-processing heat treatment typically needed for LPBF Al-Sc alloys without compromising the mechanical properties. We systematically investigated the effects of LPBF platform heating at 200 °C on the residual stress relief, microstructure, and mechanical performance of a high-strength Al-Mn-Sc alloy. The results reveal that LPBF platform heating at 200 °C is sufficient to largely relieve the process-induced residual stresses compared to parts built on an unheated 35 °C platform. Meanwhile, the platform heating triggered the dynamic precipitation of uniformly dispersed (1.5–2 nm) Sc-rich nano-clusters. Their formation in a high number density (1.75 × 1024 m−3) resulted in a ~20% improvement in tensile yield strength (522 MPa) compared to the build on the unheated platform, without sacrificing the ductility (up to 18%). The improved mechanical properties imply that platform heating at 200 °C can strengthen the LPBF-synthesised Sc-containing Al alloys via in situ aging, which is further justified by an in situ measurement study revealing that the developing temperatures in the LPBF part are within the aging temperature range of Al-Sc alloys. Without any post-LPBF treatments, these mechanical properties have proven better than those of most Al-Sc alloys through long-time post-LPBF heat treatment. Full article
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20 pages, 4754 KiB  
Article
Intrinsic Fatigue Limit and the Minimum Fatigue Crack Growth Threshold
by Mirco D. Chapetti, Nenad Gubeljak and Dražan Kozak
Materials 2023, 16(17), 5874; https://doi.org/10.3390/ma16175874 - 28 Aug 2023
Cited by 3 | Viewed by 1616
Abstract
In the field of long-life fatigue, predicting fatigue lives and limits for mechanical components is crucial for ensuring reliability and safety. Fracture mechanics tools have enabled the estimation of fatigue lives for components with small cracks or defects. However, when dealing with defects [...] Read more.
In the field of long-life fatigue, predicting fatigue lives and limits for mechanical components is crucial for ensuring reliability and safety. Fracture mechanics tools have enabled the estimation of fatigue lives for components with small cracks or defects. However, when dealing with defects larger than the microstructural characteristic size, estimating the fatigue resistance of a material requires determining the cyclic resistance curve for the defect-free matrix, which depends on knowledge of the material’s intrinsic fatigue limit. This study focuses on the experimental evidence regarding the intrinsic fatigue limit and its correlation with naturally nucleated non-propagating cracks. Fracture mechanics models for small crack propagation are introduced, and their disparities and limitations are analyzed. The concept of intrinsic fatigue limit is then introduced and applied to reanalyze a recent publication. Methods for estimating the intrinsic fatigue limit are explored and applied to experimental results reported in the literature. The need to clarify and accurately predict the intrinsic fatigue limit is highlighted in alloys where the processing generates defects larger than the microstructural size of the matrix, as often observed in materials and components produced using additive manufacturing. Full article
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