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Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components / LAUREN EDNIE

Swansea University Author: LAUREN EDNIE

  • E-Thesis – open access under embargo until: 13th May 2029

DOI (Published version): 10.23889/SUthesis.66843

Abstract

Additive manufacturing (AM) is an advanced manufacturing technique whose uptake within the aerospace industry is thought to be a key driver to reaching the UK imposed 2050 Net-Zero targets. This is being driven by the advantages that the use of AM could unlock, including but not limited to, cost sav...

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Published: Swansea University, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Lancaster, R., J.; Antonysamy, A., A.; and Mani, M., K.
URI: https://cronfa.swan.ac.uk/Record/cronfa66843
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This is being driven by the advantages that the use of AM could unlock, including but not limited to, cost savings through reduced material usage, the ability to produce components with an increased geometrical complexity and the removal of bottlenecks within conventional manufacturing processes due to reduced manufacturing times. Whilst AM can unlock numerous advantages across multiple industries, its uptake is currently being limited due to several challenges and an uncertainty within the AM mechanical performance. One of the main challenges that is being tackled is that there is currently a limited understanding of the effects of the inherent surface roughness that is seen within AM built components and the effects of this surface roughness on a component’s mechanical performance, predominantly the cyclic fatigue properties. One of the main advantages AM could unlock would be the ability to build components ready for direct placement within larger systems, but there are a number of issues that hinder this. One of the main reasons that hinder the further adoption of these methods is the high-surface roughness seen within as-built AM components. It is this high surface roughness that is thought to be the primary reason for the knockdown seen in AM fatigue performance. When coupled with inherent differences in the microstructure and build orientation effects, this knockdown when compared to the performance of conventional material is significant. Therefore, there is a need to fully understand the effects of surface roughness on the fatigue properties and the methods of surface finishing that could be applied to maximise the fatigue performance of AM material, without nullifying the benefits of this manufacturing method. Within this study the effects of the inherent AM surface roughness on the high cycle fatigue (HCF)performance of the titanium (Ti) alloy Ti-6Al-4V manufactured using various AM methods will be explored. This will include samples manufactured using Electron Beam Melting (EBM), Laser Powder Bed Fusion (LPBF) and Laser-Metal Deposition with Wire (LMD-w), with samples in both the as-built and the machined &amp; polished condition. In addition to this the impact of build orientation will also be explored, with samples built in both the horizontal (0º) and vertical (90º) orientations. The HCF test results will be supported by advanced surface profilometry, microstructural, defect and fractographic analysis. The HCF test results alongside advanced surface profilometry, microstructural, defect and fractographic analysis revealed that whilst the surface roughness in the majority of instances is the primary factor impacting the fatigue performance on AM material, it cannot be considered alone. It was found that the inherent as-built surface finish of AM material resulted in an increased number of stress-raising features upon the surface of a sample, leading to a reduction in the samples’ fatigue life, whilst machined &amp; polished material failed due to the presence of internal features. Statistical analysis of the results gained was also carried out to allow for the determination of a sample’s fatigue life outside of the testing regime completed within this work.</abstract><type>E-Thesis</type><journal/><volume/><journalNumber/><paginationStart/><paginationEnd/><publisher/><placeOfPublication>Swansea University, Wales, UK</placeOfPublication><isbnPrint/><isbnElectronic/><issnPrint/><issnElectronic/><keywords>Additive manufacturing, titanium, fatigue, surface finish.</keywords><publishedDay>13</publishedDay><publishedMonth>5</publishedMonth><publishedYear>2024</publishedYear><publishedDate>2024-05-13</publishedDate><doi>10.23889/SUthesis.66843</doi><url/><notes/><college>COLLEGE NANME</college><CollegeCode>COLLEGE CODE</CollegeCode><institution>Swansea University</institution><supervisor>Lancaster, R., J.; Antonysamy, A., A.; and Mani, M., K.</supervisor><degreelevel>Doctoral</degreelevel><degreename>EngD</degreename><degreesponsorsfunders>GKN Aerospace, Materials &amp; Manufacturing Academy</degreesponsorsfunders><apcterm/><funders>GKN Aerospace, Materials &amp; Manufacturing Academy</funders><projectreference/><lastEdited>2024-06-21T14:56:34.4922127</lastEdited><Created>2024-06-21T14:15:48.4039799</Created><path><level id="1">Faculty of Science and Engineering</level><level id="2">School of Engineering and Applied Sciences - Materials Science and Engineering</level></path><authors><author><firstname>LAUREN</firstname><surname>EDNIE</surname><order>1</order></author></authors><documents><document><filename>Under embargo</filename><originalFilename>Under embargo</originalFilename><uploaded>2024-06-21T14:32:28.8261229</uploaded><type>Output</type><contentLength>15862754</contentLength><contentType>application/pdf</contentType><version>E-Thesis – open access</version><cronfaStatus>true</cronfaStatus><embargoDate>2029-05-13T00:00:00.0000000</embargoDate><documentNotes>Copyright: The Author, Lauren Ednie, 2024</documentNotes><copyrightCorrect>true</copyrightCorrect><language>eng</language></document></documents><OutputDurs/></rfc1807>
spelling v2 66843 2024-06-21 Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components fe4eae47027aea6615987c71ffed3613 LAUREN EDNIE LAUREN EDNIE true false 2024-06-21 Additive manufacturing (AM) is an advanced manufacturing technique whose uptake within the aerospace industry is thought to be a key driver to reaching the UK imposed 2050 Net-Zero targets. This is being driven by the advantages that the use of AM could unlock, including but not limited to, cost savings through reduced material usage, the ability to produce components with an increased geometrical complexity and the removal of bottlenecks within conventional manufacturing processes due to reduced manufacturing times. Whilst AM can unlock numerous advantages across multiple industries, its uptake is currently being limited due to several challenges and an uncertainty within the AM mechanical performance. One of the main challenges that is being tackled is that there is currently a limited understanding of the effects of the inherent surface roughness that is seen within AM built components and the effects of this surface roughness on a component’s mechanical performance, predominantly the cyclic fatigue properties. One of the main advantages AM could unlock would be the ability to build components ready for direct placement within larger systems, but there are a number of issues that hinder this. One of the main reasons that hinder the further adoption of these methods is the high-surface roughness seen within as-built AM components. It is this high surface roughness that is thought to be the primary reason for the knockdown seen in AM fatigue performance. When coupled with inherent differences in the microstructure and build orientation effects, this knockdown when compared to the performance of conventional material is significant. Therefore, there is a need to fully understand the effects of surface roughness on the fatigue properties and the methods of surface finishing that could be applied to maximise the fatigue performance of AM material, without nullifying the benefits of this manufacturing method. Within this study the effects of the inherent AM surface roughness on the high cycle fatigue (HCF)performance of the titanium (Ti) alloy Ti-6Al-4V manufactured using various AM methods will be explored. This will include samples manufactured using Electron Beam Melting (EBM), Laser Powder Bed Fusion (LPBF) and Laser-Metal Deposition with Wire (LMD-w), with samples in both the as-built and the machined & polished condition. In addition to this the impact of build orientation will also be explored, with samples built in both the horizontal (0º) and vertical (90º) orientations. The HCF test results will be supported by advanced surface profilometry, microstructural, defect and fractographic analysis. The HCF test results alongside advanced surface profilometry, microstructural, defect and fractographic analysis revealed that whilst the surface roughness in the majority of instances is the primary factor impacting the fatigue performance on AM material, it cannot be considered alone. It was found that the inherent as-built surface finish of AM material resulted in an increased number of stress-raising features upon the surface of a sample, leading to a reduction in the samples’ fatigue life, whilst machined & polished material failed due to the presence of internal features. Statistical analysis of the results gained was also carried out to allow for the determination of a sample’s fatigue life outside of the testing regime completed within this work. E-Thesis Swansea University, Wales, UK Additive manufacturing, titanium, fatigue, surface finish. 13 5 2024 2024-05-13 10.23889/SUthesis.66843 COLLEGE NANME COLLEGE CODE Swansea University Lancaster, R., J.; Antonysamy, A., A.; and Mani, M., K. Doctoral EngD GKN Aerospace, Materials & Manufacturing Academy GKN Aerospace, Materials & Manufacturing Academy 2024-06-21T14:56:34.4922127 2024-06-21T14:15:48.4039799 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering LAUREN EDNIE 1 Under embargo Under embargo 2024-06-21T14:32:28.8261229 Output 15862754 application/pdf E-Thesis – open access true 2029-05-13T00:00:00.0000000 Copyright: The Author, Lauren Ednie, 2024 true eng
title Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components
spellingShingle Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components
LAUREN EDNIE
title_short Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components
title_full Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components
title_fullStr Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components
title_full_unstemmed Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components
title_sort Understanding the Effects of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components
author_id_str_mv fe4eae47027aea6615987c71ffed3613
author_id_fullname_str_mv fe4eae47027aea6615987c71ffed3613_***_LAUREN EDNIE
author LAUREN EDNIE
author2 LAUREN EDNIE
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doi_str_mv 10.23889/SUthesis.66843
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
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
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description Additive manufacturing (AM) is an advanced manufacturing technique whose uptake within the aerospace industry is thought to be a key driver to reaching the UK imposed 2050 Net-Zero targets. This is being driven by the advantages that the use of AM could unlock, including but not limited to, cost savings through reduced material usage, the ability to produce components with an increased geometrical complexity and the removal of bottlenecks within conventional manufacturing processes due to reduced manufacturing times. Whilst AM can unlock numerous advantages across multiple industries, its uptake is currently being limited due to several challenges and an uncertainty within the AM mechanical performance. One of the main challenges that is being tackled is that there is currently a limited understanding of the effects of the inherent surface roughness that is seen within AM built components and the effects of this surface roughness on a component’s mechanical performance, predominantly the cyclic fatigue properties. One of the main advantages AM could unlock would be the ability to build components ready for direct placement within larger systems, but there are a number of issues that hinder this. One of the main reasons that hinder the further adoption of these methods is the high-surface roughness seen within as-built AM components. It is this high surface roughness that is thought to be the primary reason for the knockdown seen in AM fatigue performance. When coupled with inherent differences in the microstructure and build orientation effects, this knockdown when compared to the performance of conventional material is significant. Therefore, there is a need to fully understand the effects of surface roughness on the fatigue properties and the methods of surface finishing that could be applied to maximise the fatigue performance of AM material, without nullifying the benefits of this manufacturing method. Within this study the effects of the inherent AM surface roughness on the high cycle fatigue (HCF)performance of the titanium (Ti) alloy Ti-6Al-4V manufactured using various AM methods will be explored. This will include samples manufactured using Electron Beam Melting (EBM), Laser Powder Bed Fusion (LPBF) and Laser-Metal Deposition with Wire (LMD-w), with samples in both the as-built and the machined & polished condition. In addition to this the impact of build orientation will also be explored, with samples built in both the horizontal (0º) and vertical (90º) orientations. The HCF test results will be supported by advanced surface profilometry, microstructural, defect and fractographic analysis. The HCF test results alongside advanced surface profilometry, microstructural, defect and fractographic analysis revealed that whilst the surface roughness in the majority of instances is the primary factor impacting the fatigue performance on AM material, it cannot be considered alone. It was found that the inherent as-built surface finish of AM material resulted in an increased number of stress-raising features upon the surface of a sample, leading to a reduction in the samples’ fatigue life, whilst machined & polished material failed due to the presence of internal features. Statistical analysis of the results gained was also carried out to allow for the determination of a sample’s fatigue life outside of the testing regime completed within this work.
published_date 2024-05-13T14:56:33Z
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