A bioinspired method for fatigue crack path tailoring and life enhancement in metals via additive manufacturing Show others and affiliations
2025 (English) In: Materials & design, ISSN 0264-1275, E-ISSN 1873-4197, Vol. 258, article id 114561Article in journal (Refereed) Published
Abstract [en]
Inspired by natural systems, weak features can be strategically incorporated into materials to enhance mechanical response. This study presents, for the first time, a bioinspired approach enabled by additive manufacturing to tailor crack paths and enhance fatigue life in metallic components. Cylindrical holes of varying diameters and patterns were embedded as site-specific weak features in 18Ni(300) maraging steel produced via laser powder bed fusion. Fatigue crack growth tests in solution-annealed and aged conditions revealed that a region of weak features can effectively tailor crack path in solution-annealed condition while improving fatigue life in both conditions. In solution-annealed condition, crack deviation, bifurcation and transition of fatigue crack growth stage improved the fatigue life by 26%. In the aged condition, however, the lower fracture toughness limited the crack path tailoring, and retardation due to the crack re-initiation enhanced fatigue life by 14%. In both conditions, rough surfaces of holes restricted the maximum fatigue life improvement. This study demonstrates the unique potential of AM to integrate weak features into metallic materials for crack engineering. By refining the holes roughness in further steps, crack engineering via AM can be realized, offering a pathway to further optimize components’ durability.
Place, publisher, year, edition, pages Elsevier, 2025. Vol. 258, article id 114561
Keywords [en]
Bioinspiration; Weak features; Crack engineering; Crack path tailoring; Fatigue life enhancement; Additive manufacturing
National Category
Manufacturing, Surface and Joining Technology
Research subject Production Technology
Identifiers URN: urn:nbn:se:hv:diva-24457 DOI: 10.1016/j.matdes.2025.114561 ISI: 001583200500003 Scopus ID: 2-s2.0-105013333422 OAI: oai:DiVA.org:hv-24457 DiVA, id: diva2:2026477
Note CC BY
2026-01-092026-01-092026-01-09