Prediction of Failure Due to Fatigue of Wire Arc Additive Manufacturing-Manufactured Product

Abstract

Currently, the focus of production is shifting towards the use of innovative manufacturing techniques and away from traditional methods. Additive manufacturing technologies hold great promise for creating industrial products. The industry aims to enhance the reliability of individual components and structural elements, as well as the ability to accurately anticipate component failure, particularly due to fatigue. This paper explores the possibility of predicting component failure in parts produced using the WAAM (wire arc additive manufacturing) method by employing fractal dimension analysis. Additionally, the impact of manufacturing imperfections and various heat treatment processes on the fatigue resistance of 30CrMnSi steel has been investigated. Fatigue testing of samples and actual components fabricated via the WAAM process was conducted in this study. The destruction of the examined specimens and products was predicted by evaluating the fractal dimensions of micrographs acquired at different stages of fatigue testing. It has been established that technological defects are more dangerous in terms of fatigue failure than microstructural ones. The correctly selected mode of heat treatment for metal after electric arc welding allows for a more homogeneous microstructure with a near-complete absence of microstructural defects. A comparison of the fractal dimension method with other damage assessment methods shows that it has high accuracy in predicting part failure and is less labor-intensive than other methods.