Uniaxial Tensile Performance in the Presence of a Defect: Prediction Through a Defect-Tolerant Design Framework

The inherent imperfections introduced during the manufacturing processes of casting, welding, and additive manufacturing often result in compromised mechanical properties. The concentrated deformation around these defects during loading significantly impacts tensile ductility and fatigue performance. This study introduces an innovative defect-tolerant design approach for predicting the uniaxial tensile behaviour of ADC12 aluminium alloys. Employing precise micro-drilling techniques, a deliberately created flaw is strategically positioned at the midpoint along the central axis of the rectangular uniaxial tensile test specimen. The proposed methodology accurately forecasts uniaxial tensile elongation, ultimate tensile strength, and the entire stress–strain curve for materials affected by defects.