Effects of process interruptions on mechanical properties and failure mechanisms of L-PBF Ti-6Al-4V specimens and the restorative role of heat treatment

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-04-08 DOI:10.1016/j.engfailanal.2025.109594

Zhongming Zhuo , Lei Wang , Jian Mao

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引用次数: 0

Abstract

In the field of metal additive manufacturing (AM), laser powder bed fusion (L-PBF) technology is widely employed for the fabrication of complex metal components due to its precision and versatility. However, during the production process, interruptions may frequently occur due to factors such as power outages, insufficient gas flow, or sensor malfunctions. To address potential economic losses, it is crucial to understand the impact of build interruptions on part quality and implement effective measures to resume production. This study investigates the variations in key mechanical properties and fracture mechanisms of Ti-6Al-4V alloy specimens fabricated by L-PBF under interrupted build conditions, and evaluates heat treatment methods to alleviate the detrimental impacts of such interruptions. Our results indicate that build interruptions significantly reduce the strength and toughness of the specimens, while only minimally affecting microstructure and hardness. Fracture site analysis through fractography and cross-sectional examination revealed that all untreated samples failed precisely at the interruption site. The study recommends a cyclic heat treatment method that can successfully enhance fracture performance at the interruption site and recovers the strength and toughness of the specimens to comparable levels with uninterrupted samples.

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工艺中断对L-PBF Ti-6Al-4V试样力学性能和失效机制的影响及热处理的恢复作用

在金属增材制造（AM）领域，激光粉末床熔融（L-PBF）技术因其精度和通用性被广泛应用于复杂金属部件的制造。然而，在生产过程中，由于停电、气体流量不足或传感器故障等因素，经常会出现中断。为了解决潜在的经济损失，了解制造中断对零件质量的影响并采取有效措施恢复生产是至关重要的。研究了L-PBF断口条件下Ti-6Al-4V合金试样关键力学性能和断裂机制的变化，并评价了缓解断口不利影响的热处理方法。我们的研究结果表明，构建中断显著降低了试样的强度和韧性，而对显微组织和硬度的影响很小。通过断口分析和横断面检查发现，所有未经处理的样品都精确地在中断位置失效。该研究推荐了一种循环热处理方法，该方法可以成功地提高中断部位的断裂性能，并将试样的强度和韧性恢复到与不间断试样相当的水平。

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

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.