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Microstructural influence on fatigue crack propagation during high cycle fatigue testing of additively manufactured Alloy 718
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.ORCID iD: 0000-0002-8664-4573
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Linköping University, Department of Management and Engineering, Linköping, Sweden.ORCID iD: 0000-0002-8304-0221
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
Linköping University, Department of Management and Engineering, Linköping, Sweden.
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2019 (English)In: Materials Characterization, ISSN 1044-5803, E-ISSN 1873-4189, Vol. 149, p. 82-94Article in journal (Refereed) Published
Abstract [en]

A study of the microstructure of additively manufactured Alloy 718 was performed in order to better understand the parameters that have an influence on the fatigue properties of the material. The specimens were manufactured using two powder bed fusion techniques – Electron Beam Melting (EBM) and Selective Laser Melting (SLM). Four point bending fatigue tests were performed at room temperature with a stress ratio of R = 0.1 and 20 Hz frequency, on material that was either in hot isostatically pressed (HIP) and solution treated and aged (STA) condition or in STA condition without a prior HIP treatment. The grains in the SLM material in the HIP + STA condition have grown considerably both in the hatch and the contour regions; EBM material, in contrast, shows grain growth only in the contour region. Fractographic analysis of the specimens in HIP + STA condition showed a faceted appearance while the specimens in STA condition showed a more planar crack appearance. The crack propagation occurred in a transgranular mode and it was found that precipitatessuch as NbC, TiN or δ-phase, when present, did not affect the crack path. The areas with larger grains corresponded to the faceted appearance of the fracture surface. This could be attributed to the plastic zone ahead of the crack tip being confined within one grain, in case of the larger grains, which promotes single shear crack growth mode

Place, publisher, year, edition, pages
2019. Vol. 149, p. 82-94
Keywords [en]
Electron beam melting, Selective laser melting, Alloy 718, Fatigue crack propagation, Microstructure, Hot isostatic pressing
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-13460DOI: 10.1016/j.matchar.2019.01.018ISI: 000475837800008Scopus ID: 2-s2.0-85060346504OAI: oai:DiVA.org:hv-13460DiVA, id: diva2:1285495
Funder
Knowledge Foundation, 20160281Available from: 2019-02-04 Created: 2019-02-04 Last updated: 2020-11-16Bibliographically approved
In thesis
1. Towards understanding the fatigue behaviour of Alloy 718 manufactured by Powder Bed Fusion processes
Open this publication in new window or tab >>Towards understanding the fatigue behaviour of Alloy 718 manufactured by Powder Bed Fusion processes
2020 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Additive Manufacturing (AM) is a disruptive modern manufacturing process in which parts are manufactured in a layer-wise fashion. Among the metal AM processes, Powder Bed Fusion (PBF) technology — comprised of Electron Beam Powder Bed Fusion (EB-PBF) and Laser Beam Powder Bed Fusion (LB-PBF) —has opened up a design space that was formerly unavailable with conventionalmanufacturing processes. PBF processes offer several advantages; however, thesuitability of these processes to replace the conventional processes must be investigatedin detail. Therefore, understanding the AM process – post-processing –microstructure – property relationships is crucial for the manufacturing of high performance components. In this regard, only limited work has been done towards understanding the fatigue behaviour of PBF Alloy 718. The aim of this work, therefore, is to understand how the fatigue behaviour of PBF Alloy 718 is affected by its microstructure. Besides, the influence of the rough as-built surface is also investigated. In general, the <100> fibre texture along the build direction that resulted from PBF processing of Alloy 718 led to anisotropy in Young's modulus. Consequently,the fatigue performance under controlled amplitudes of strain was anisotropic such that the low-modulus direction had longer fatigue life and vice versa. This texture-induced elasticity-dependent anisotropic strain-life behaviour couldbe normalized by the pseudo-elastic stress vs fatigue life approach.Inclusions and defects had a detrimental effect on fatigue performance. Numerousfactors, such as their geometry, volume fraction, and distribution, determinedthe effect on fatigue behaviour. Hot Isostatic Pressing (HIP) eliminated most defect sand led to an improvement in fatigue performance. However, HIP did not alter the inclusions, which acted as crack initiation sites and reduced fatigue life. The rough as-built surface, which had numerous notch-like crack initiation sites, deteriorated fatigue performance; however, it lowered the scatter in fatigue life. Machining off the as-built surface improved fatigue life but increased the scatter.

Place, publisher, year, edition, pages
Trollhättan: University West, 2020. p. 79
Series
PhD Thesis: University West ; 42
Keywords
Fatigue; Additive Manufacturing; Powder Bed Fusion; Superalloy; Microstructure; Surface Roughness
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-16034 (URN)978-91-88847-79-9 (ISBN)978-91-88847-78-2 (ISBN)
Public defence
2020-12-08, Albertssalen, Trollhättan, 13:00 (English)
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Tillstånd till elektronisk publicering finns för samtliga artiklar

Available from: 2020-11-16 Created: 2020-11-16 Last updated: 2020-11-16Bibliographically approved

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Balachandramurthi, Arun RamanathanMoverare, JohanDixit, NikhilPederson, Robert

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