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<p>Titanium alloys, particularly Ti-6Al-4V, are widely used in high-performance applications owing to their high specific strength, corrosion resistance, and suitability for additive manufacturing (AM). Electron beam melting (EBM) enables the fabrication of complex geometries, yet the influence of build location and surface condition on fatigue behavior remains insufficiently characterized. This study evaluates the high-cycle fatigue (HCF) performance of Ti-6Al-4V specimens produced by EBM in the Z-build direction, focusing on two parameters: radial distance from the build platform center and surface condition (as-built vs. machined). Fatigue tests were performed under tension–compression loading (R = 0.1) at stress levels ranging from 130 to 600 MPa. Machined specimens exhibited substantially improved fatigue life, reaching ∼5 × 10<sup>6</sup> cycles at 240 MPa and showing an approximate fatigue limit of ∼240 MPa, compared to ∼140 MPa for as-built specimens. No systematic variation in fatigue life was observed with radial position. These findings demonstrate that surface finish plays a dominant role in fatigue performance, whereas radial build location within a 360 mm platform has negligible influence. The results provide practical insight for optimizing post-processing strategies and improving the fatigue reliability of EBM-fabricated Ti-6Al-4V components for aerospace and other fatigue-critical applications.</p>

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Fatigue strength of Ti-6Al-4V parts produced by EBM: Effects of position and machining

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Serpil Tabak Memiç,
  • Bilçen Mutlu Mitil

摘要

Titanium alloys, particularly Ti-6Al-4V, are widely used in high-performance applications owing to their high specific strength, corrosion resistance, and suitability for additive manufacturing (AM). Electron beam melting (EBM) enables the fabrication of complex geometries, yet the influence of build location and surface condition on fatigue behavior remains insufficiently characterized. This study evaluates the high-cycle fatigue (HCF) performance of Ti-6Al-4V specimens produced by EBM in the Z-build direction, focusing on two parameters: radial distance from the build platform center and surface condition (as-built vs. machined). Fatigue tests were performed under tension–compression loading (R = 0.1) at stress levels ranging from 130 to 600 MPa. Machined specimens exhibited substantially improved fatigue life, reaching ∼5 × 106 cycles at 240 MPa and showing an approximate fatigue limit of ∼240 MPa, compared to ∼140 MPa for as-built specimens. No systematic variation in fatigue life was observed with radial position. These findings demonstrate that surface finish plays a dominant role in fatigue performance, whereas radial build location within a 360 mm platform has negligible influence. The results provide practical insight for optimizing post-processing strategies and improving the fatigue reliability of EBM-fabricated Ti-6Al-4V components for aerospace and other fatigue-critical applications.