| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
|
| Symposium
|
Additive Manufacturing Fatigue and Fracture: Towards Accurate Prediction
|
| Presentation Title |
Fracture-Based Fatigue Life Prediction of Additively Manufactured Parts with As-Built Surface Roughness |
| Author(s) |
Leland Shimizu, Xueyong Qu, Jacob Rome |
| On-Site Speaker (Planned) |
Leland Shimizu |
| Abstract Scope |
Additively manufactured (AM) parts are increasingly used with as-printed surfaces in the aerospace industry. One challenge resulting from the use of as-printed AM surfaces is degraded fatigue life caused by surface roughness. Traditional fracture-based approaches of assessing fatigue life can struggle to analyze shallow surface defects characteristic of surface roughness due to the complexities of small crack effects.
This paper explores modifications to the fracture-based approach to correct for small crack effects using an in-house developed crack growth code. Three modifications are explored: 1) addition of a small material dependent increment to the crack length, 2) addition of the cyclic plastic zone size to the crack length, and 3) elimination of crack closure effects for small cracks. Deterministic and probabilistic fatigue life predictions are calculated based on the variation in pit depth of the as-printed surface. Predictions are then benchmarked against fatigue test results of as-printed coupons. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Modeling and Simulation, |