A multiscale crystal plasticity-multistage fatigue coupling framework for prediction of low-cycle fatigue life in laser additively manufactured titanium alloy
Existing aerospace fatigue life models inadequately predict high-strain cycle failures in TC11 titanium alloys due to overlooked dynamic microstructural evolution and multiscale damage, undermining critical airframe safety assessments. This study introduces a novel multiscale framework that synergis...
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| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
| Subjects: | |
| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2025.2521103 |
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| Summary: | Existing aerospace fatigue life models inadequately predict high-strain cycle failures in TC11 titanium alloys due to overlooked dynamic microstructural evolution and multiscale damage, undermining critical airframe safety assessments. This study introduces a novel multiscale framework that synergistically integrates microstructure-sensitive crystal plasticity (CP) with a multistage fatigue (MSF) model to accurately predict the low-cycle fatigue (LCF) life of TC11 alloy fabricated via laser powder-directed energy deposition (LP-DED). The CP-MSF model synergistically integrates microstructure deformation mechanisms and heterogeneous plasticity-induced damage evolution from CP analysis with MSF's multiscale variable transmission framework, establishing a holistic framework that quantitatively captures dynamic microstructure evolution, crack nucleation-propagation transitions, and scale-dependent damage interactions. The validity of the proposed framework was tested against strain-life curves, demonstrating a mean prediction error about 4.6% across a range of strain amplitudes (0.4%–1.2%). This study further elucidates the individual contributions of microstructure morphology, α lath size and micro-orientation to LCF lifetime. Notably, the presence of basketweave microstructure and coarse α laths significantly enhances LCF life, whereas the micro-orientation has less effect. Additionally, Schmid factor (SF) analyses and intragranular misorientation axes (IGMA) investigations identified Pyramidal I slip as the predominant deformation mechanism under cyclic loading. |
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| ISSN: | 1745-2759 1745-2767 |