Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built Materials
MIL-STD-1530D and the United States Air Force (USAF) Structures Bulletin EZ-SB-19-01 require an ability to predict the growth of naturally occurring three-dimensional cracks with crack depths equal to what they term an equivalent initial damage size (EIDS) of 0.254 mm. This requirement holds for bot...
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MDPI AG
2025-06-01
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| Online Access: | https://www.mdpi.com/2073-4352/15/6/544 |
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| author | Shareen Chan Daren Peng Andrew S. M. Ang Michael B. Nicholas Victor K. Champagne Aron Birt Alex Michelson Sean Langan Jarrod Watts Rhys Jones |
| author_facet | Shareen Chan Daren Peng Andrew S. M. Ang Michael B. Nicholas Victor K. Champagne Aron Birt Alex Michelson Sean Langan Jarrod Watts Rhys Jones |
| author_sort | Shareen Chan |
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| description | MIL-STD-1530D and the United States Air Force (USAF) Structures Bulletin EZ-SB-19-01 require an ability to predict the growth of naturally occurring three-dimensional cracks with crack depths equal to what they term an equivalent initial damage size (EIDS) of 0.254 mm. This requirement holds for both additively manufactured and conventionally built parts. The authors have previously presented examples of how to perform such predictions for additively manufactured (AM) Ti-6Al-4V; wire arc additively manufactured (WAAM) 18Ni 250 Maraging steel; and Boeing Space, Intelligence and Weapon Systems laser bed powder fusion (LPBF) Scalmalloy<sup>®</sup>, which is an additively manufactured Aluminium-Scandium-Mg alloy, using the Hartman-Schijve crack growth equation. In these studies, the constants used were as determined from ASTM E647 standard tests on long cracks, and the fatigue threshold term in the Hartman-Schijve equation was set to a small value (namely, 0.1 MPa √m). This paper illustrates how this approach can also be used to predict the growth of naturally occurring three-dimensional cracks in WAAM CP-Ti (commercially pure titanium) specimens built by Solvus Global as well as in WAAM-built Inconel 718. As in the prior studies mentioned above, the constants used in this analysis were taken from prior studies into the growth of long cracks in conventionally manufactured CP-Ti and in AM Inconel 718, and the fatigue threshold term in these analyses was set to 0.1 MPa √m. These studies are complemented via a prediction of the growth of naturally occurring three-dimensional cracks in conventionally built M300 steel. |
| format | Article |
| id | doaj-art-e809a4fba12e446588ec1658d97a77c5 |
| institution | Kabale University |
| issn | 2073-4352 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Crystals |
| spelling | doaj-art-e809a4fba12e446588ec1658d97a77c52025-08-20T03:27:18ZengMDPI AGCrystals2073-43522025-06-0115654410.3390/cryst15060544Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built MaterialsShareen Chan0Daren Peng1Andrew S. M. Ang2Michael B. Nicholas3Victor K. Champagne4Aron Birt5Alex Michelson6Sean Langan7Jarrod Watts8Rhys Jones9ARC Industrial Transformation Training Centre on Surface Engineering for Advanced Materials, Faculty of Science, Engineering and Technology, Swinburne University of Technology, John Street, Hawthorn, VIC 3122, AustraliaARC Industrial Transformation Training Centre on Surface Engineering for Advanced Materials, Faculty of Science, Engineering and Technology, Swinburne University of Technology, John Street, Hawthorn, VIC 3122, AustraliaARC Industrial Transformation Training Centre on Surface Engineering for Advanced Materials, Faculty of Science, Engineering and Technology, Swinburne University of Technology, John Street, Hawthorn, VIC 3122, AustraliaUS Army Research Laboratory, U.S. Army Combat Capabilities Development Command Weapons and Materials Research Directorate, Aberdeen Proving Ground, Aberdeen, MD 21005, USAUS Army Research Laboratory, U.S. Army Combat Capabilities Development Command Weapons and Materials Research Directorate, Aberdeen Proving Ground, Aberdeen, MD 21005, USASolvus Global, 104 Prescott Street, Worcester, MA 01605, USASolvus Global, 104 Prescott Street, Worcester, MA 01605, USASolvus Global, 104 Prescott Street, Worcester, MA 01605, USARosebank Engineering Australia, 836 Mountain Highway, Bayswater, VIC 315, AustraliaARC Industrial Transformation Training Centre on Surface Engineering for Advanced Materials, Faculty of Science, Engineering and Technology, Swinburne University of Technology, John Street, Hawthorn, VIC 3122, AustraliaMIL-STD-1530D and the United States Air Force (USAF) Structures Bulletin EZ-SB-19-01 require an ability to predict the growth of naturally occurring three-dimensional cracks with crack depths equal to what they term an equivalent initial damage size (EIDS) of 0.254 mm. This requirement holds for both additively manufactured and conventionally built parts. The authors have previously presented examples of how to perform such predictions for additively manufactured (AM) Ti-6Al-4V; wire arc additively manufactured (WAAM) 18Ni 250 Maraging steel; and Boeing Space, Intelligence and Weapon Systems laser bed powder fusion (LPBF) Scalmalloy<sup>®</sup>, which is an additively manufactured Aluminium-Scandium-Mg alloy, using the Hartman-Schijve crack growth equation. In these studies, the constants used were as determined from ASTM E647 standard tests on long cracks, and the fatigue threshold term in the Hartman-Schijve equation was set to a small value (namely, 0.1 MPa √m). This paper illustrates how this approach can also be used to predict the growth of naturally occurring three-dimensional cracks in WAAM CP-Ti (commercially pure titanium) specimens built by Solvus Global as well as in WAAM-built Inconel 718. As in the prior studies mentioned above, the constants used in this analysis were taken from prior studies into the growth of long cracks in conventionally manufactured CP-Ti and in AM Inconel 718, and the fatigue threshold term in these analyses was set to 0.1 MPa √m. These studies are complemented via a prediction of the growth of naturally occurring three-dimensional cracks in conventionally built M300 steel.https://www.mdpi.com/2073-4352/15/6/544naturally occurring 3D cracksfatigue crack growthadditive manufacturingMIL-STD-1530DcHartman-Schijve crack growth equation |
| spellingShingle | Shareen Chan Daren Peng Andrew S. M. Ang Michael B. Nicholas Victor K. Champagne Aron Birt Alex Michelson Sean Langan Jarrod Watts Rhys Jones Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built Materials Crystals naturally occurring 3D cracks fatigue crack growth additive manufacturing MIL-STD-1530Dc Hartman-Schijve crack growth equation |
| title | Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built Materials |
| title_full | Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built Materials |
| title_fullStr | Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built Materials |
| title_full_unstemmed | Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built Materials |
| title_short | Further Studies into the Growth of Small Naturally Occurring Three-Dimensional Cracks in Additively Manufactured and Conventionally Built Materials |
| title_sort | further studies into the growth of small naturally occurring three dimensional cracks in additively manufactured and conventionally built materials |
| topic | naturally occurring 3D cracks fatigue crack growth additive manufacturing MIL-STD-1530Dc Hartman-Schijve crack growth equation |
| url | https://www.mdpi.com/2073-4352/15/6/544 |
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