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Fatigue Failure from Inner Surfaces of Additive Manufactured Ti-6Al-4V Components

datacite.subject.fosCiências Naturais::Ciências Físicas
datacite.subject.fosCiências Naturais::Outras Ciências Naturais
datacite.subject.sdg07:Energias Renováveis e Acessíveis
datacite.subject.sdg11:Cidades e Comunidades Sustentáveis
dc.contributor.authorJesus, Joel de
dc.contributor.authorFerreira, José António Martins
dc.contributor.authorBorrego, Luís
dc.contributor.authorCosta, José D.
dc.contributor.authorCapela, Carlos
dc.date.accessioned2026-04-08T11:25:26Z
dc.date.available2026-04-08T11:25:26Z
dc.date.issued2021-02-05
dc.description.abstractSelective laser melting (SLM) is an additive manufacturing process for producing metallic components with complex geometries. A drawback of this process is the process-inherent poor surface finish, which is highly detrimental in materials submitted to fatigue loading situations. The goal of this work is to analyze the fatigue behavior of Ti-6Al-4V specimens with internal axial channels under the following different conditions: hole drilled, hole as manufactured, and hole threaded M4 × 0.7. All the cases studied showed a lower fatigue performance as compared with solid samples due to the surface roughness and geometry effect that produced a surface stress concentration leading to a reduction in fatigue strength. The fractography revealed that crack initiation occurred from the internal surface in all specimens with internal channel mostly from defects as unfused particles and lack of fusion zones, while for the solid specimens crack initiation was observed from the external surface due to insufficient fusion defect. The application of the Smith-Watson-Topper energy-based parameter was revealed to be a good tool for fatigue life prediction of the different series studied.eng
dc.description.sponsorshipThe authors would like to acknowledge the sponsoring under project no. 028789, financed by the European Regional Development Fund (FEDER), through the Portugal 2020 program (PT2020), under the Regional Operational Program of the Center (CENTRO-01-0145-FEDER-028789). This research is also sponsored by FEDER funds through the program COMPETE, Programa Operacional Factores de Competitividade, and by national funds through FCT, Fundação para a Ciência e a Tecnologia, under project UIDB/00285/2020. Finally, the authors acknowledge the project POCI-01-0247-FEDER-042536, financed by European Funds, through program COMPETE2020, under the Eureka smart label S0129-AddDies.
dc.identifier.citationde Jesus, J.; Martins Ferreira, J.A.; Borrego, L.; Costa, J.D.; Capela, C. Fatigue Failure from Inner Surfaces of Additive Manufactured Ti-6Al-4V Components. Materials 2021, 14, 737. https://doi.org/10.3390/ma14040737.
dc.identifier.doi10.3390/ma14040737
dc.identifier.eissn1996-1944
dc.identifier.urihttp://hdl.handle.net/10400.8/16071
dc.language.isoeng
dc.peerreviewedyes
dc.publisherMDPI
dc.relationCentre for Mechanical Enginnering, Materials and Processes
dc.relation.hasversionhttps://www.mdpi.com/1996-1944/14/4/737
dc.relation.ispartofMaterials
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/
dc.subjectadditive manufacturing
dc.subjectfatigue
dc.subjectTiAl6V4 alloy
dc.subjectfatigue life prediction
dc.titleFatigue Failure from Inner Surfaces of Additive Manufactured Ti-6Al-4V Componentseng
dc.typejournal article
dspace.entity.typePublication
oaire.awardNumberUIDB/00285/2020
oaire.awardTitleCentre for Mechanical Enginnering, Materials and Processes
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDB%2F00285%2F2020/PT
oaire.citation.endPage12
oaire.citation.issue4
oaire.citation.startPage1
oaire.citation.titleMaterials
oaire.citation.volume14
oaire.fundingStream6817 - DCRRNI ID
oaire.versionhttp://purl.org/coar/version/c_970fb48d4fbd8a85
person.familyNameCapela
person.givenNameCarlos
person.identifier.ciencia-id9B1E-6857-3D6B
person.identifier.orcid0000-0003-3334-4945
person.identifier.ridG-6395-2016
person.identifier.scopus-author-id7801358401
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.nameFundação para a Ciência e a Tecnologia
relation.isAuthorOfPublication9b079aa3-b79b-4395-b081-1f23d6a17514
relation.isAuthorOfPublication.latestForDiscovery9b079aa3-b79b-4395-b081-1f23d6a17514
relation.isProjectOfPublication0a3418ca-35b9-4670-a826-154cceca5a89
relation.isProjectOfPublication.latestForDiscovery0a3418ca-35b9-4670-a826-154cceca5a89

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Selective laser melting (SLM) is an additive manufacturing process for producing metallic components with complex geometries. A drawback of this process is the process-inherent poor surface finish, which is highly detrimental in materials submitted to fatigue loading situations. The goal of this work is to analyze the fatigue behavior of Ti-6Al-4V specimens with internal axial channels under the following different conditions: hole drilled, hole as manufactured, and hole threaded M4 × 0.7. All the cases studied showed a lower fatigue performance as compared with solid samples due to the surface roughness and geometry effect that produced a surface stress concentration leading to a reduction in fatigue strength. The fractography revealed that crack initiation occurred from the internal surface in all specimens with internal channel mostly from defects as unfused particles and lack of fusion zones, while for the solid specimens crack initiation was observed from the external surface due to insufficient fusion defect. The application of the Smith-Watson-Topper energy-based parameter was revealed to be a good tool for fatigue life prediction of the different series studied.
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