Enhancing fatigue performance of laser powder bed fused metals through controlling contour parameters and structures

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-01-09 DOI:10.1016/j.ijfatigue.2025.108811

Hongzhuang Zhang, Changyou Li, Shujie Cao, Ivan Sergeichev, Guian Qian

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引用次数: 0

Abstract

Side surface quality is a critical concern in the fatigue performance of laser powder bed fused (PBF-LB) components. Increasing contour passes with customized parameters along sample edge can tune side surface/subsurface quality and thereby enhance fatigue resistance. This study critically evaluates the surface and subsurface characteristics resulting from varying contour parameters and their impact on the fatigue performance of PBF-LB 304L steel through multiple detailed characterizations. The fatigue damage mechanisms for varying contour parameters are investigated through fatigue fractography, temperature field analysis, and microstructural evolution. Results indicate that optimal contour parameters differed from infill parameters due to the energy absorption from powder fusion and solidification remelting. The contour defects, including spherical vapor cavities and irregular lack-of-fusion (LoF) defects resulting from inappropriate parameters, significantly degrade fatigue lifetime due to their high-stress concentration factors. Appropriate contour parameters (approximately 300 J/mm3 in energy density) can minimize defect content while simultaneously enhancing microstructural heterogeneity in the contour region. The identified physical mechanisms of defect formation and fatigue damage will assist in designing and optimizing contour process for enhancing fatigue performance.

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通过控制激光粉末床熔敷金属的轮廓参数和结构来提高其疲劳性能

侧面质量是影响激光粉末床熔合（PBF-LB）部件疲劳性能的关键因素。增加沿样品边缘定制参数的轮廓道次可以调整侧面/次表面质量，从而提高抗疲劳性。本研究通过多种详细表征，批判性地评估了由不同轮廓参数引起的PBF-LB 304L钢的表面和地下特征及其对疲劳性能的影响。通过疲劳断口分析、温度场分析和显微组织演化等研究了不同轮廓参数下的疲劳损伤机理。结果表明，由于粉末熔合和凝固重熔的能量吸收，最佳轮廓参数与填充参数存在差异。轮廓缺陷，包括球形汽腔和不规则的LoF缺陷，由于参数不合适而导致的高应力集中系数，显著降低了疲劳寿命。适当的轮廓参数（能量密度约为300 J/mm3）可以最大限度地减少缺陷含量，同时增强轮廓区域的微结构非均质性。识别缺陷形成和疲劳损伤的物理机制将有助于轮廓工艺的设计和优化，以提高疲劳性能。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.