Fatigue in Additive Manufactured Metals

1st Edition - September 20, 2023
Editors: Filippo Berto, Anton Du Plessis
Language: English
Paperback ISBN:
9 7 8 - 0 - 3 2 3 - 9 1 2 0 4 - 4
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 9 9 8 3 1 - 4

Fatigue in Additive Manufactured Metals provides a brief overview of the fundamental mechanics involved in metal fatigue and fracture, assesses the unique properties of additive… Read more

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Fatigue in Additive Manufactured Metals provides a brief overview of the fundamental mechanics involved in metal fatigue and fracture, assesses the unique properties of additive manufactured metals, and provides an in-depth exploration of how and why fatigue occurs in additive manufactured metals. Additional sections cover solutions for preventing it, best-practice design methods, and more. The book recommends cutting-edge evidence-based approaches for designing longer lasting additive manufactured metals, discusses the latest trends in the field and the various aspects of low cycle fatigue, and looks at both post-treatment and manufacturing process-based solutions.

By providing international standards and testing procedures of additive manufactured metal parts and discussing the environmental impacts of additive manufacturing of metals and outlining simulation and modeling scenarios, this book is an ideal resource for users in industry.

Cover image
Title page
Table of Contents
Copyright
List of contributors
1. Introduction
Abstract
2. Introduction to metal additive manufacturing and unique aspects relating to fatigue
Abstract
2.1 Introduction
2.2 Metal additive manufacturing processes and materials
2.3 Porosity
2.4 Surface roughness and texture
2.5 Residual stress
2.6 Microstructure
2.7 Manufacturing errors
2.8 Postprocessing
2.9 Conclusion
References
3. Low-cycle fatigue of additive manufactured metals
Abstract
Nomenclature
3.1 Introduction
3.2 Literature review
3.3 Cyclic stress–strain behavior
3.4 Stable stress–strain response
3.5 Fatigue life relationships
3.6 Fracture surfaces and failure mechanisms
3.7 Cyclic plasticity modeling
3.8 Fatigue life prediction
Acknowledgments
References
4. Fatigue and corrosion-fatigue crack growth behavior of wire arc additively manufactured parts
Abstract
Nomenclature
4.1 Introduction
4.2 Materials and fabrication method
4.3 Test set-up
4.4 Experimental results and discussion
4.5 Conclusions
Acknowledgments
References
5. Fatigue behavior in the presence of defects
Abstract
Nomenclature
5.1 Introduction on defects and additive manufacturing
5.2 Brief classification of additive manufacturing defects
5.3 Influence of defects on the fatigue response
5.4 Modeling the fatigue strength in the presence of defects
5.5 Implications on the design against fatigue failures
5.6 Concluding remarks
References
6. Analytical methods and computational approaches for modeling the fatigue behavior of additively manufactured materials
Abstract
6.1 Analytical methods on the effect of volumetric defects
6.2 Analytical methods on the effect of surface defects
6.3 Numerical approaches on the effect of microstructure
6.4 An outlook on future enhanced hybrid defect/microstructure-sensitive fatigue models
6.5 Summary
References
7. Very high cycle fatigue of additive manufacturing metals
Abstract
Nomenclature
7.1 Introduction to very high cycle fatigue
7.2 AlSi12
7.3 AlSi10Mg and AlSi7Mg
7.4 Ti6Al4V
7.5 Inconel 718
7.6 Stainless steel 316 L
7.7 Conclusions and final remarks
References
8. Defects in additive manufacturing and their influence on structural integrity
Abstract
8.1 Additive manufacturing processes
8.2 Powder bed fusion category
8.3 Process parameters
8.4 Type of defects in additive manufacturing components
8.5 Impact of defects on mechanical performances
8.6 Conclusions
References
9. Post treatments for improving fatigue performance
Abstract
9.1 Introduction
9.2 Surface post treatments
9.3 Heat treatments
9.4 Summary and conclusions
References
10. A review of the effects of laser shock peening on properties of additively manufactured Ti6Al4V
Abstract
10.1 Introduction
10.2 Laser shock peening parameters
10.3 Effects of laser shock peening on Ti6Al4V
10.4 Summary and recommendations for future work
References
11. Mechanical properties of lattice materials for fatigue-tolerant design and fabrication
Abstract
11.1 Introduction
11.2 Geometry and monotonic behavior of lattice structures
11.3 Experimental evaluation of fatigue behavior of lattice structures
11.4 Experimental assessment of fatigue-related aspects
11.5 Design against fatigue
11.6 Fatigue prediction methodologies
11.7 Advanced design of additive manufacturing lattice structures against fatigue
11.8 Summary and outlook
References
Index

Filippo Berto

Professor Filippo Berto is chair in mechanics of materials at Sapienza University of Rome, Italy. He was professor of machine design at the University of Padua, Italy, between 2006 and 2015. He is chairman of the technical committee ESIS TC15 on Structural Integrity of additive manufactured components of European Structural Integrity Society. Filippo Berto received several awards and distinctions, such as Award of Merit (2018) and Wohler medal (2020) from the European Structural Integrity Society. He has received the Stephen Timoshenko Fellow (2018) given by University of Stanford (USA). Filippo Berto is part of the Top Italian Scientists Engineering (Italy). He is editor-in-chief or Editor of several scientific journals, such as, Fatigue & Fracture of Engineering Materials & Structures, Material Design & Processing Communications and Materials. In addition, he belongs to the editorial board of several leading scientific journals in the area of fatigue, fracture and structural integrity, such as, Materials & Design, International Journal of Fatigue, Safety Science, Theoretical and Applied Fracture Mechanics, Materials Science and Engineering: A, Advanced Engineering Materials, Polymer Testing, Strength of Materials, among others. He is also collaborating with the Centre of Excellence of additive manufacturing established in Auburn and in particular with Prof. Nima Shamsaei and Dr. Mohsen Seifi who is chair of additive manufacturing programs in ASTM. Filippo Berto is also voting member of ASTM F42 on Additive Manufacturing Technologies and ASTM E08 on Metal Fatigue and Fracture. As technical Chair of TC15 is also the founder of the series of European conferences on additive manufacturing ESIAM.

Affiliations and expertise

Chair in mechanics of materials, Sapienza University of Rome, Italy

Anton Du Plessis

Prof. Anton Du Plessis is Associate Professor at Stellenbosch University (South Africa) and Applications Scientist at Object Research Systems (Canada). His research spans X-ray tomography applications, additive manufacturing and engineering materials. He has published over 150 journal papers and is on the editorial board of a number of journals, and acts as deputy editor of Additive Manufacturing Letters and editor in chief of Tomography of Materials and Structures. He holds extraordinary professor positions at Nelson Mandela University and Central University of Technology (South Africa).

Affiliations and expertise

Applications Scientist, Object Research Systems Inc, Montreal, Quebec, Canada; Associate Professor, Research Group 3D Innovation, Stellenbosch University, Stellenbosch, Western Cape, South Africa

Life Sciences

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