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<p>The size effect on the four-point bending fatigue lives of additive manufactured TC4 alloy was investigated. Four-point bending fatigue tests, fracture analysis, and finite element simulations were conducted on samples of varying sizes. The results show that the fatigue lives do not differ obviously with changing sample sizes, indicating the insensitivity of the stress gradient to fatigue lives for the additive manufactured TC4 alloy. The fatigue fractures show that fatigue cracks mainly initiate from lack of fusion (LOF) defects near the sample surface for different sized samples. Moreover, the stress induced by four-point bending fatigue is concentrated within a thin surface layer, effectively reducing the dimensional relevance of the size effect from three dimensions to two. This dimensional reduction further diminishes the influence of specimen size on fatigue performance. Therefore, it is inferred that the combined effect of the randomness in the defects and the localized surface stress distribution contributes to the insensitivity of four-point bending fatigue lives to sample size in additive manufactured TC4 alloys.</p>

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Insensitivity of Fatigue Lives to Stress Gradient in Additive Manufacturing TC4 Alloy

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Yining Zhang,
  • Jiapeng Hou,
  • Xiaotao Li,
  • Zhan Qu,
  • Yankun Zhu,
  • Xin Bai,
  • Hanzhong Liu,
  • Zhenkai Zhao,
  • Lijia Chen,
  • Zhenjun Zhang,
  • Zhefeng Zhang

摘要

The size effect on the four-point bending fatigue lives of additive manufactured TC4 alloy was investigated. Four-point bending fatigue tests, fracture analysis, and finite element simulations were conducted on samples of varying sizes. The results show that the fatigue lives do not differ obviously with changing sample sizes, indicating the insensitivity of the stress gradient to fatigue lives for the additive manufactured TC4 alloy. The fatigue fractures show that fatigue cracks mainly initiate from lack of fusion (LOF) defects near the sample surface for different sized samples. Moreover, the stress induced by four-point bending fatigue is concentrated within a thin surface layer, effectively reducing the dimensional relevance of the size effect from three dimensions to two. This dimensional reduction further diminishes the influence of specimen size on fatigue performance. Therefore, it is inferred that the combined effect of the randomness in the defects and the localized surface stress distribution contributes to the insensitivity of four-point bending fatigue lives to sample size in additive manufactured TC4 alloys.