Fatigue crack initiation in additively manufactured maraging steel: A statistical insight

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-03-26 DOI:10.1016/j.ijfatigue.2025.108957

Chitresh Chandra, Vidit Gaur

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Abstract

High cycle fatigue tests were performed on three different-sized, laser powder bed fusion (L-PBF) fabricated MS1 maraging steel specimens at room temperature and at a stress ratio of −1, with qualitative and statistical investigation of the defect size and shape on the fatigue lives. The mechanical and fatigue properties were not much affected by the change in gauge volumes (128, 250, 432 mm³) investigated in this study owing to the similar distribution of the internal porosities. Interestingly, the manufacturing defects were mostly present near the free surface of the L-PBF fabricated parts instead of being uniformly distributed within the control volume. A significant scatter in the fatigue life data was attributed to the geometric parameters: shape, size, and location of the crack-initiating defects within the fractured specimens. The ratio of the defects’ size to their location with respect to the free surface was found to dictate the total fatigue life. The probabilistic S-N curves based on two popular models: the Weibull model and the Stüssi model, were plotted in addition to the conventional Murakami’s model to predict the fatigue life and strength. Conclusively, the Stüssi Model appeared to generate a safer fatigue design curve with the broadest bandwidth covering the experimentally observed uncertainties. The obtained results showed a good correlation with the experimental results and established the reliability of the research.

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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.