Fatigue crack propagation is critical in engineering components. Additive manufacturing techniques like Selective Laser Melting (SLM), Laser Engineered Net Shaping (LENS), and Wire Arc Additive Manufacturing (WAAM) enable fabricating complex structures, particularly from costly materials like titanium and nickel alloys. In this work, a WAAM setup is fabricated to deposit material using gas metal arc welding. This study examines WAAM-fabricated Ti-6Al-4V components, focusing on how welding parameters—current, voltage, and speed—affect fatigue properties. Fatigue crack propagation rates (FCGR) were analyzed using compact tension (CT) tests in different orientations. One sample exhibited crack growth along the longitudinal direction, while the other propagated transversely. Results revealed FCGR dependency on microstructure and hardness, with large grains (3–4 mm) in the build direction and smaller grains (100–167 µm) transversely. Mechanical property variations across orientations influenced fatigue behaviour, aligning with observed tensile properties. These findings highlight the role of microstructural differences in crack propagation behaviour within WAAM-fabricated components.

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Fatigue Crack Propagation Behaviour in Different Orientation of WAAM Fabricated Ti-6Al-4V Components

  • Hemant Kaundal,
  • Tarun Kumar Bera,
  • Ratnesh Kumar Raj Singh

摘要

Fatigue crack propagation is critical in engineering components. Additive manufacturing techniques like Selective Laser Melting (SLM), Laser Engineered Net Shaping (LENS), and Wire Arc Additive Manufacturing (WAAM) enable fabricating complex structures, particularly from costly materials like titanium and nickel alloys. In this work, a WAAM setup is fabricated to deposit material using gas metal arc welding. This study examines WAAM-fabricated Ti-6Al-4V components, focusing on how welding parameters—current, voltage, and speed—affect fatigue properties. Fatigue crack propagation rates (FCGR) were analyzed using compact tension (CT) tests in different orientations. One sample exhibited crack growth along the longitudinal direction, while the other propagated transversely. Results revealed FCGR dependency on microstructure and hardness, with large grains (3–4 mm) in the build direction and smaller grains (100–167 µm) transversely. Mechanical property variations across orientations influenced fatigue behaviour, aligning with observed tensile properties. These findings highlight the role of microstructural differences in crack propagation behaviour within WAAM-fabricated components.