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Fatigue crack growth behaviour of wire arc additively manufactured steels

Publikation: Beitrag in FachzeitschriftArtikelForschungPeer-Review

Autorschaft

  • Cheng Huang
  • Yuanpeng Zheng
  • Tao Chen
  • Elyas Ghafoori

Organisationseinheiten

Externe Organisationen

  • Imperial College London
  • Tongji University
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OriginalspracheEnglisch
Aufsatznummer107705
FachzeitschriftInternational journal of fatigue
Jahrgang173
Frühes Online-Datum6 Mai 2023
PublikationsstatusVeröffentlicht - Aug. 2023

Abstract

Combining welding technology with robotics, wire arc additive manufacturing (WAAM) is emerging as a viable method of construction. To facilitate its wider application, in particular with structural integrity in mind, an improved understanding of the fatigue properties of WAAM materials is needed. Hence, an experimental investigation into the fatigue crack growth (FCG) behaviour of WAAM plates made of normal- and high-strength steels has been conducted and is reported herein. Following material characterisation, FCG tests on 13 machined compact tension specimens were undertaken, extracted in different directions from WAAM plates built using a parallel deposition strategy. Fractography of the tested specimens was also performed to analyse the mechanisms of crack growth. The material testing demonstrated an approximately proportional relationship between the hardness and ultimate strength. From the FCG tests, Paris’ law constants were derived for the WAAM normal- and high-strength steel specimens, revealing consistently lower material constants m for the latter. Similar FCG behaviour to that of equivalent, conventionally-produced steels, with no significant anisotropy, was found. The observed response was shown to be generally well captured by the FCG laws given in BS 7910, with the recommended curve for unwelded steels providing a close match to the experimental data and the recommended curve for welded steels providing conservative predictions. Additional FCG data on WAAM steels printed using the parallel and oscillatory deposition strategies were collected and analysed. It was shown that the two deposition strategies led to similar crack growth rates for WAAM normal-strength steels, but distinct FCG behavioural trends for WAAM high-strength steels. Finally, the fractographic analysis showed that the WAAM specimens exhibited principally brittle behaviour during FCG but somewhat ductile behaviour before fracture.

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Fatigue crack growth behaviour of wire arc additively manufactured steels. / Huang, Cheng; Zheng, Yuanpeng; Chen, Tao et al.
in: International journal of fatigue, Jahrgang 173, 107705, 08.2023.

Publikation: Beitrag in FachzeitschriftArtikelForschungPeer-Review

Huang C, Zheng Y, Chen T, Ghafoori E, Gardner L. Fatigue crack growth behaviour of wire arc additively manufactured steels. International journal of fatigue. 2023 Aug;173:107705. Epub 2023 Mai 6. doi: 10.1016/j.ijfatigue.2023.107705
Huang, Cheng ; Zheng, Yuanpeng ; Chen, Tao et al. / Fatigue crack growth behaviour of wire arc additively manufactured steels. in: International journal of fatigue. 2023 ; Jahrgang 173.
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title = "Fatigue crack growth behaviour of wire arc additively manufactured steels",
abstract = "Combining welding technology with robotics, wire arc additive manufacturing (WAAM) is emerging as a viable method of construction. To facilitate its wider application, in particular with structural integrity in mind, an improved understanding of the fatigue properties of WAAM materials is needed. Hence, an experimental investigation into the fatigue crack growth (FCG) behaviour of WAAM plates made of normal- and high-strength steels has been conducted and is reported herein. Following material characterisation, FCG tests on 13 machined compact tension specimens were undertaken, extracted in different directions from WAAM plates built using a parallel deposition strategy. Fractography of the tested specimens was also performed to analyse the mechanisms of crack growth. The material testing demonstrated an approximately proportional relationship between the hardness and ultimate strength. From the FCG tests, Paris{\textquoteright} law constants were derived for the WAAM normal- and high-strength steel specimens, revealing consistently lower material constants m for the latter. Similar FCG behaviour to that of equivalent, conventionally-produced steels, with no significant anisotropy, was found. The observed response was shown to be generally well captured by the FCG laws given in BS 7910, with the recommended curve for unwelded steels providing a close match to the experimental data and the recommended curve for welded steels providing conservative predictions. Additional FCG data on WAAM steels printed using the parallel and oscillatory deposition strategies were collected and analysed. It was shown that the two deposition strategies led to similar crack growth rates for WAAM normal-strength steels, but distinct FCG behavioural trends for WAAM high-strength steels. Finally, the fractographic analysis showed that the WAAM specimens exhibited principally brittle behaviour during FCG but somewhat ductile behaviour before fracture.",
keywords = "Additive manufacturing, Compact tension specimen, Fatigue crack propagation, Metal 3D printing, Wire arc additive manufacturing",
author = "Cheng Huang and Yuanpeng Zheng and Tao Chen and Elyas Ghafoori and Leroy Gardner",
note = "Funding Information: This research was possible thanks to funding and support from the European Union's Horizon 2020 research and innovation programme under grant agreement No. 820776 {\textquoteleft}Intelligent data driven pipeline for the manufacturing of certified metal parts through Direct Energy Deposition process (INTEGRADDE).{\textquoteright} The authors also gratefully acknowledge MX3D for the provision of the test specimens. ",
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journal = "International journal of fatigue",
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TY - JOUR

T1 - Fatigue crack growth behaviour of wire arc additively manufactured steels

AU - Huang, Cheng

AU - Zheng, Yuanpeng

AU - Chen, Tao

AU - Ghafoori, Elyas

AU - Gardner, Leroy

N1 - Funding Information: This research was possible thanks to funding and support from the European Union's Horizon 2020 research and innovation programme under grant agreement No. 820776 ‘Intelligent data driven pipeline for the manufacturing of certified metal parts through Direct Energy Deposition process (INTEGRADDE).’ The authors also gratefully acknowledge MX3D for the provision of the test specimens.

PY - 2023/8

Y1 - 2023/8

N2 - Combining welding technology with robotics, wire arc additive manufacturing (WAAM) is emerging as a viable method of construction. To facilitate its wider application, in particular with structural integrity in mind, an improved understanding of the fatigue properties of WAAM materials is needed. Hence, an experimental investigation into the fatigue crack growth (FCG) behaviour of WAAM plates made of normal- and high-strength steels has been conducted and is reported herein. Following material characterisation, FCG tests on 13 machined compact tension specimens were undertaken, extracted in different directions from WAAM plates built using a parallel deposition strategy. Fractography of the tested specimens was also performed to analyse the mechanisms of crack growth. The material testing demonstrated an approximately proportional relationship between the hardness and ultimate strength. From the FCG tests, Paris’ law constants were derived for the WAAM normal- and high-strength steel specimens, revealing consistently lower material constants m for the latter. Similar FCG behaviour to that of equivalent, conventionally-produced steels, with no significant anisotropy, was found. The observed response was shown to be generally well captured by the FCG laws given in BS 7910, with the recommended curve for unwelded steels providing a close match to the experimental data and the recommended curve for welded steels providing conservative predictions. Additional FCG data on WAAM steels printed using the parallel and oscillatory deposition strategies were collected and analysed. It was shown that the two deposition strategies led to similar crack growth rates for WAAM normal-strength steels, but distinct FCG behavioural trends for WAAM high-strength steels. Finally, the fractographic analysis showed that the WAAM specimens exhibited principally brittle behaviour during FCG but somewhat ductile behaviour before fracture.

AB - Combining welding technology with robotics, wire arc additive manufacturing (WAAM) is emerging as a viable method of construction. To facilitate its wider application, in particular with structural integrity in mind, an improved understanding of the fatigue properties of WAAM materials is needed. Hence, an experimental investigation into the fatigue crack growth (FCG) behaviour of WAAM plates made of normal- and high-strength steels has been conducted and is reported herein. Following material characterisation, FCG tests on 13 machined compact tension specimens were undertaken, extracted in different directions from WAAM plates built using a parallel deposition strategy. Fractography of the tested specimens was also performed to analyse the mechanisms of crack growth. The material testing demonstrated an approximately proportional relationship between the hardness and ultimate strength. From the FCG tests, Paris’ law constants were derived for the WAAM normal- and high-strength steel specimens, revealing consistently lower material constants m for the latter. Similar FCG behaviour to that of equivalent, conventionally-produced steels, with no significant anisotropy, was found. The observed response was shown to be generally well captured by the FCG laws given in BS 7910, with the recommended curve for unwelded steels providing a close match to the experimental data and the recommended curve for welded steels providing conservative predictions. Additional FCG data on WAAM steels printed using the parallel and oscillatory deposition strategies were collected and analysed. It was shown that the two deposition strategies led to similar crack growth rates for WAAM normal-strength steels, but distinct FCG behavioural trends for WAAM high-strength steels. Finally, the fractographic analysis showed that the WAAM specimens exhibited principally brittle behaviour during FCG but somewhat ductile behaviour before fracture.

KW - Additive manufacturing

KW - Compact tension specimen

KW - Fatigue crack propagation

KW - Metal 3D printing

KW - Wire arc additive manufacturing

UR - http://www.scopus.com/inward/record.url?scp=85159096092&partnerID=8YFLogxK

U2 - 10.1016/j.ijfatigue.2023.107705

DO - 10.1016/j.ijfatigue.2023.107705

M3 - Article

AN - SCOPUS:85159096092

VL - 173

JO - International journal of fatigue

JF - International journal of fatigue

SN - 0142-1123

M1 - 107705

ER -

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