Simulated effect of defect volume and location on very high cycle fatigue of laser beam powder bed fused AlSi10Mg

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-03-08 DOI:10.1016/j.ijfatigue.2025.108926

Kamin Tahmasbi , Mohammadreza Yaghoobi , Shuai Shao , Nima Shamsaei , Meysam Haghshenas

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引用次数: 0

Abstract

This study quantifies the interaction between volumetric defect location and size on the very high cycle fatigue (VHCF) of laser beam powder bed fused (LB-PBF) AlSi10Mg. Crystal plasticity finite element method (CPFEM) simulations were used to investigate the effects of defect location and size on the driving force for crack initiation. The CPFEM model was calibrated against uniaxial and cyclic experimental data of LB-PBF AlSi10Mg. Defect characteristics were informed by experimental data from the specimens produced in various geometries to create realistic representative volume elements (RVEs) with equivalent volume fractions of defects. By embedding defects of varying sizes and locations within the RVEs, fatigue indicator parameters (FIPs) were calculated to analyze the impact of defects’ characteristics on fatigue performance. Different combinations of defect volume and locations were generated for various microstructure instantiations, providing insight into extreme value fatigue responses. Larger defect volumes located on free surfaces consistently generated the highest FIPs, suggesting defect size and boundary proximity intensify stress concentration effects. RVEs with multiple smaller defects produced lower FIPs than those with single large critical defects. These findings underscore the critical role of defect characteristics on fatigue life, providing a foundation for future predictive modeling in fatigue-sensitive AM applications.

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模拟了缺陷体积和位置对AlSi10Mg激光束粉末床熔焊高周疲劳的影响

本研究量化了体积缺陷位置和尺寸对AlSi10Mg激光粉末床熔敷（LB-PBF）极高周疲劳（VHCF）的影响。采用晶体塑性有限元法（CPFEM）模拟研究了缺陷位置和尺寸对裂纹起裂驱动力的影响。根据LB-PBF AlSi10Mg的单轴和循环实验数据对CPFEM模型进行了校准。从不同几何形状的试样中获得的实验数据可以告知缺陷特征，从而创建具有等效缺陷体积分数的现实代表性体积单元（RVEs）。通过在RVEs中嵌入不同尺寸和位置的缺陷，计算疲劳指标参数（FIPs），分析缺陷特征对疲劳性能的影响。针对不同的微观结构实例，生成了不同的缺陷体积和位置组合，从而深入了解极值疲劳响应。位于自由表面的较大缺陷体积始终产生最高的FIPs，这表明缺陷尺寸和边界接近加剧了应力集中效应。具有多个较小缺陷的rve比具有单个较大关键缺陷的rve产生更低的FIPs。这些发现强调了缺陷特征对疲劳寿命的关键作用，为疲劳敏感增材制造应用的未来预测建模提供了基础。

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.