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Fracture, Fatigue and Wear

FFW 2018: Proceedings of the 7th International Conference on Fracture Fatigue and Wear pp 297–313Cite as

Comparative Study of Defect-Based and Plastic Damage-Based Approaches for Fatigue Lifetime Calculation of Selective Laser-Melted AlSi12

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Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Abstract

Selective laser melting is an additive layer manufacturing process based on powder bed fusion using high-energy laser beams. Process features constitute very finely grained cellular and columnar dendritic microstructure in aluminum alloy AlSi12. Melt pool instabilities produce porosity of the keyhole and metallurgical types. Both structural characteristics are investigated in this study using crack propagation-based and plastic damage-based approaches. The aim is to separate influences of microstructure and defects on the fatigue lifetime concerning the fatigue regime of interest. Process-induced defects for two batches of selective laser-melted AlSi12 were investigated using micro-computed tomography. The influence of platform heating during deposition is a subject of study concerning fatigue strength. The results showed that platform heating reduces the amount of remnant porosity and fatigue strength scatter. Fatigue lifetime calculation, based on crack propagation curves and weakest-link theory, was found consistent with low-cycle fatigue experiments. However, prediction of lifetimes using damage monitoring in a load increase test, as well as a Monte-Carlo simulation, produced more relevant results in the low-cycle to high-cycle fatigue range. The difference was consideration of damage in the pre-crack initiation phase in the plasticity-based approach of the load increase test.

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Acknowledgements

The authors would like to thank the German Research Foundation for its financial support to the conduct of this research work in terms of a research grant entitled: “Mechanism-based understanding of functional grading focused on fatigue behavior of additively processed Ti-6Al-4V and Al-12Si alloys” (WA 1672/25-1; EM 95/2-1).

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Authors and Affiliations

  1. Department of Materials Test Engineering (WPT), TU Dortmund University, Dortmund, Germany

    M. Awd, S. Siddique, R. Hajavifard & F. Walther

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  1. M. Awd
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  4. F. Walther
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Correspondence to M. Awd .

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  1. Faculty of Engineering and Architecture, Ghent University , Ghent, Belgium

    Magd Abdel Wahab

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Awd, M., Siddique, S., Hajavifard, R., Walther, F. (2019). Comparative Study of Defect-Based and Plastic Damage-Based Approaches for Fatigue Lifetime Calculation of Selective Laser-Melted AlSi12. In: Abdel Wahab, M. (eds) Proceedings of the 7th International Conference on Fracture Fatigue and Wear. FFW 2018. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-13-0411-8_27

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  • DOI: https://doi.org/10.1007/978-981-13-0411-8_27

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  • Online ISBN: 978-981-13-0411-8

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