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The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V

Lauren Ednie, Robert Lancaster Orcid Logo, A.A. Antonysamy, F. Zelenka, A. Scarpellini, L. Parimi, R. Maddalena, Nick Barnard, P. Efthymiadis

Materials Science and Engineering: A, Volume: 857, Start page: 144050

Swansea University Authors: Lauren Ednie, Robert Lancaster Orcid Logo, Nick Barnard

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DOI (Published version): 10.1016/j.msea.2022.144050

Abstract

Additive manufacturing (AM) is an advanced manufacturing technique whose uptake within the aerospace industry is being limited by the lack of understanding of the effects of surface finish on the fatigue properties of AM built components. It is known that the surface profile of as-built AM parts is...

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Published in: Materials Science and Engineering: A
ISSN: 0921-5093
Published: Elsevier BV 2022
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URI: https://cronfa.swan.ac.uk/Record/cronfa61280
first_indexed 2022-09-20T08:10:42Z
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It is known that the surface profile of as-built AM parts is significantly rougher than its traditionally manufactured equivalent, promoting stress raising features that have an adverse effect on fatigue life. This paper will focus on developing a deeper understanding of the fatigue properties of the widely-used alpha-beta titanium alloy, Ti-6Al-4V, as manufactured through electron beam melting (EBM) and the role that surface roughness plays. Results have been generated on as-built and machined &amp; polished EBM test coupons, supported by microstructural and fractographic analysis, X-ray computed tomography (XCT), advanced surface profilometry and hardness testing. Results have shown that as-built EBM Ti-6Al-4V samples have a significantly inferior fatigue life than machined &amp; polished samples, despite the material in each of the surface finish types being hot isostatically pressed (HIP). It has been revealed that while surface parameters, MR2 and Ra, provide no correlation to high cycle fatigue life, it is shown that as the Rp surface parameter decreases, the respective number of cycles to failure increases. It can be concluded that a samples&#x2019; surface roughness is a highly contributing factor in influencing fatigue performance, yet it should not be considered in isolation since other features, including porosity, also play an important role.</abstract><type>Journal Article</type><journal>Materials Science and Engineering: A</journal><volume>857</volume><journalNumber/><paginationStart>144050</paginationStart><paginationEnd/><publisher>Elsevier BV</publisher><placeOfPublication/><isbnPrint/><isbnElectronic/><issnPrint>0921-5093</issnPrint><issnElectronic/><keywords>Electron Beam Melting; Ti-6Al-4V; Fatigue; Surface Roughness</keywords><publishedDay>1</publishedDay><publishedMonth>11</publishedMonth><publishedYear>2022</publishedYear><publishedDate>2022-11-01</publishedDate><doi>10.1016/j.msea.2022.144050</doi><url/><notes/><college>COLLEGE NANME</college><CollegeCode>COLLEGE CODE</CollegeCode><institution>Swansea University</institution><apcterm>SU College/Department paid the OA fee</apcterm><funders>The current research was funded by the Materials and Manufacturing Academy, M2A, (grant number: c80816) supported by the European Social fund through the Welsh Government. 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spelling 2022-10-27T12:15:51.9667919 v2 61280 2022-09-20 The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V 8d34318252ba316f7887d108cfb15544 Lauren Ednie Lauren Ednie true false e1a1b126acd3e4ff734691ec34967f29 0000-0002-1365-6944 Robert Lancaster Robert Lancaster true false dc4a58e614bc6a1d99812a3acfdd9034 Nick Barnard Nick Barnard true false 2022-09-20 Additive manufacturing (AM) is an advanced manufacturing technique whose uptake within the aerospace industry is being limited by the lack of understanding of the effects of surface finish on the fatigue properties of AM built components. It is known that the surface profile of as-built AM parts is significantly rougher than its traditionally manufactured equivalent, promoting stress raising features that have an adverse effect on fatigue life. This paper will focus on developing a deeper understanding of the fatigue properties of the widely-used alpha-beta titanium alloy, Ti-6Al-4V, as manufactured through electron beam melting (EBM) and the role that surface roughness plays. Results have been generated on as-built and machined & polished EBM test coupons, supported by microstructural and fractographic analysis, X-ray computed tomography (XCT), advanced surface profilometry and hardness testing. Results have shown that as-built EBM Ti-6Al-4V samples have a significantly inferior fatigue life than machined & polished samples, despite the material in each of the surface finish types being hot isostatically pressed (HIP). It has been revealed that while surface parameters, MR2 and Ra, provide no correlation to high cycle fatigue life, it is shown that as the Rp surface parameter decreases, the respective number of cycles to failure increases. It can be concluded that a samples’ surface roughness is a highly contributing factor in influencing fatigue performance, yet it should not be considered in isolation since other features, including porosity, also play an important role. Journal Article Materials Science and Engineering: A 857 144050 Elsevier BV 0921-5093 Electron Beam Melting; Ti-6Al-4V; Fatigue; Surface Roughness 1 11 2022 2022-11-01 10.1016/j.msea.2022.144050 COLLEGE NANME COLLEGE CODE Swansea University SU College/Department paid the OA fee The current research was funded by the Materials and Manufacturing Academy, M2A, (grant number: c80816) supported by the European Social fund through the Welsh Government. The provision of a research bursary, materials and supporting information from GKN Additive is gratefully acknowledged. The assistance provided by the Swansea University AIM Facility and the Welsh Coating and Printing Centre, which was funded in part by the EPSRC, are also much appreciated. 2022-10-27T12:15:51.9667919 2022-09-20T08:47:05.6834408 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Lauren Ednie 1 Robert Lancaster 0000-0002-1365-6944 2 A.A. Antonysamy 3 F. Zelenka 4 A. Scarpellini 5 L. Parimi 6 R. Maddalena 7 Nick Barnard 8 P. Efthymiadis 9 61280__25323__b2d516b6b5d64391b33523e100e9a64e.pdf 61280_VoR.pdf 2022-10-06T12:06:38.7943650 Output 21856323 application/pdf Version of Record true © 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY license true eng http://creativecommons.org/licenses/by/4.0/
title The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V
spellingShingle The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V
Lauren Ednie
Robert Lancaster
Nick Barnard
title_short The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V
title_full The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V
title_fullStr The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V
title_full_unstemmed The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V
title_sort The effects of surface finish on the fatigue performance of electron beam melted Ti–6Al–4V
author_id_str_mv 8d34318252ba316f7887d108cfb15544
e1a1b126acd3e4ff734691ec34967f29
dc4a58e614bc6a1d99812a3acfdd9034
author_id_fullname_str_mv 8d34318252ba316f7887d108cfb15544_***_Lauren Ednie
e1a1b126acd3e4ff734691ec34967f29_***_Robert Lancaster
dc4a58e614bc6a1d99812a3acfdd9034_***_Nick Barnard
author Lauren Ednie
Robert Lancaster
Nick Barnard
author2 Lauren Ednie
Robert Lancaster
A.A. Antonysamy
F. Zelenka
A. Scarpellini
L. Parimi
R. Maddalena
Nick Barnard
P. Efthymiadis
format Journal article
container_title Materials Science and Engineering: A
container_volume 857
container_start_page 144050
publishDate 2022
institution Swansea University
issn 0921-5093
doi_str_mv 10.1016/j.msea.2022.144050
publisher Elsevier BV
college_str Faculty of Science and Engineering
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hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
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description Additive manufacturing (AM) is an advanced manufacturing technique whose uptake within the aerospace industry is being limited by the lack of understanding of the effects of surface finish on the fatigue properties of AM built components. It is known that the surface profile of as-built AM parts is significantly rougher than its traditionally manufactured equivalent, promoting stress raising features that have an adverse effect on fatigue life. This paper will focus on developing a deeper understanding of the fatigue properties of the widely-used alpha-beta titanium alloy, Ti-6Al-4V, as manufactured through electron beam melting (EBM) and the role that surface roughness plays. Results have been generated on as-built and machined & polished EBM test coupons, supported by microstructural and fractographic analysis, X-ray computed tomography (XCT), advanced surface profilometry and hardness testing. Results have shown that as-built EBM Ti-6Al-4V samples have a significantly inferior fatigue life than machined & polished samples, despite the material in each of the surface finish types being hot isostatically pressed (HIP). It has been revealed that while surface parameters, MR2 and Ra, provide no correlation to high cycle fatigue life, it is shown that as the Rp surface parameter decreases, the respective number of cycles to failure increases. It can be concluded that a samples’ surface roughness is a highly contributing factor in influencing fatigue performance, yet it should not be considered in isolation since other features, including porosity, also play an important role.
published_date 2022-11-01T12:26:33Z
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