Huang, C., Li, L., Pichler, N. et al. (3 more authors) (2023) Fatigue testing and analysis of steel plates manufactured by wire-arc directed energy deposition. Additive Manufacturing, 73. 103696. ISSN 2214-7810
Abstract
Wire-arc directed energy deposition (DED), also known as wire-arc additive manufacturing (WAAM), is a metal 3D printing technique that is recognised for its high efficiency, cost-effectiveness, flexibility in build scales and suitability for the construction sector. However, there remains a lack of fundamental data on the structural performance of WAAM elements, especially regarding their fatigue behaviour. A comprehensive experimental study into the fatigue behaviour of WAAM steel plates has therefore been undertaken and is reported herein. Following geometric, mechanical and microstructural characterisation, a series of WAAM coupons was tested under uniaxial high-cycle fatigue loading. A total of 75 fatigue tests on both as-built and machined coupons, covering various stress ranges and stress ratios (R = 0.1, 0.2, 0.3 and 0.4), have been conducted. The local stress concentrations in the as-built coupons induced by their surface undulations have also been studied by numerical simulations. The fatigue test results were analysed using constant life diagrams (CLDs) and S-N (stress-life) diagrams, based on both nominal and local stresses. The CLDs revealed that the fatigue strength of the as-built WAAM steel was relatively insensitive to the different stress ratios. The S-N diagrams showed that the surface undulations resulted in a reduction of about 35% in the fatigue endurance limit for the as-built WAAM material relative to the machined material, and a reduction of about 60% in fatigue life under the same load level. The as-built and machined WAAM coupons were shown to exhibit similar fatigue behaviour to conventional steel butt welds and S355 structural steel plates, respectively. Preliminary nominal stress-based and local stress-based S-N curves were also proposed for the WAAM steel.
Metadata
Item Type: | Article |
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Authors/Creators: |
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Copyright, Publisher and Additional Information: | © 2023 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/). |
Keywords: | Directed energy deposition (DED); Experiments; Fatigue life; Geometric variability; Metal 3D printing; Stress concentrations |
Dates: |
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Institution: | The University of Sheffield |
Academic Units: | The University of Sheffield > Faculty of Engineering (Sheffield) > Department of Civil and Structural Engineering (Sheffield) |
Depositing User: | Symplectic Sheffield |
Date Deposited: | 18 Jul 2023 11:38 |
Last Modified: | 18 Jul 2023 11:38 |
Status: | Published |
Publisher: | Elsevier |
Refereed: | Yes |
Identification Number: | 10.1016/j.addma.2023.103696 |
Open Archives Initiative ID (OAI ID): | oai:eprints.whiterose.ac.uk:201555 |