Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy
Residual stress (RS) in laser powder bed fusion (LPBF) additive manufactured structures can significantly affect mechanical performance, potentially leading to premature failure. The complex distribution of residual stresses, combined with the limitations of full-field measurement techniques, presen...
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MDPI AG
2025-01-01
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| Series: | Aerospace |
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| Online Access: | https://www.mdpi.com/2226-4310/12/2/103 |
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| author | Wenbo Sun Yu’e Ma Peiyao Li Weihong Zhang |
| author_facet | Wenbo Sun Yu’e Ma Peiyao Li Weihong Zhang |
| author_sort | Wenbo Sun |
| collection | DOAJ |
| description | Residual stress (RS) in laser powder bed fusion (LPBF) additive manufactured structures can significantly affect mechanical performance, potentially leading to premature failure. The complex distribution of residual stresses, combined with the limitations of full-field measurement techniques, presents a substantial challenge in conducting damage tolerance analyses of aircraft structures. To address these challenges, this study developed a comprehensive simulation framework to analyze the 3D distribution of residual stresses and fatigue crack growth in LPBF parts. The 3D residual stress profiles of as-built samples in 15° and 75° build directions were computed and compared to experimental data. The fatigue crack propagation behavior of the 75° sample, considering 3D residual stress, was predicted, and the effects of residual stress redistribution under cyclic loading were discussed. It shows that the anisotropy of residual stress, influenced by the build direction, can lead to mixed-mode fracture and subsequent crack deflection. Tensile residual stress in the near-surface region and compressive stress in the inner region can cause an inverted elliptical crack front and accelerate fatigue crack growth. |
| format | Article |
| id | doaj-art-553ef561c35c4c7dbb3a338fe81cc61a |
| institution | DOAJ |
| issn | 2226-4310 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Aerospace |
| spelling | doaj-art-553ef561c35c4c7dbb3a338fe81cc61a2025-08-20T02:44:47ZengMDPI AGAerospace2226-43102025-01-0112210310.3390/aerospace12020103Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V AlloyWenbo Sun0Yu’e Ma1Peiyao Li2Weihong Zhang3State IJR Center of Aerospace Design and Additive Manufacturing, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, ChinaSchool of Aeronautics, Northwestern Polytechnical University, Xi’an 710072, ChinaSchool of Aeronautics, Northwestern Polytechnical University, Xi’an 710072, ChinaState IJR Center of Aerospace Design and Additive Manufacturing, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, ChinaResidual stress (RS) in laser powder bed fusion (LPBF) additive manufactured structures can significantly affect mechanical performance, potentially leading to premature failure. The complex distribution of residual stresses, combined with the limitations of full-field measurement techniques, presents a substantial challenge in conducting damage tolerance analyses of aircraft structures. To address these challenges, this study developed a comprehensive simulation framework to analyze the 3D distribution of residual stresses and fatigue crack growth in LPBF parts. The 3D residual stress profiles of as-built samples in 15° and 75° build directions were computed and compared to experimental data. The fatigue crack propagation behavior of the 75° sample, considering 3D residual stress, was predicted, and the effects of residual stress redistribution under cyclic loading were discussed. It shows that the anisotropy of residual stress, influenced by the build direction, can lead to mixed-mode fracture and subsequent crack deflection. Tensile residual stress in the near-surface region and compressive stress in the inner region can cause an inverted elliptical crack front and accelerate fatigue crack growth.https://www.mdpi.com/2226-4310/12/2/103residual stresslaser powder bed fusionfatigue crackTi6Al4V alloy |
| spellingShingle | Wenbo Sun Yu’e Ma Peiyao Li Weihong Zhang Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy Aerospace residual stress laser powder bed fusion fatigue crack Ti6Al4V alloy |
| title | Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy |
| title_full | Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy |
| title_fullStr | Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy |
| title_full_unstemmed | Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy |
| title_short | Residual Stress Distribution and Its Effect on Fatigue Crack Path of Laser Powder Bed Fusion Ti6Al4V Alloy |
| title_sort | residual stress distribution and its effect on fatigue crack path of laser powder bed fusion ti6al4v alloy |
| topic | residual stress laser powder bed fusion fatigue crack Ti6Al4V alloy |
| url | https://www.mdpi.com/2226-4310/12/2/103 |
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