Using marker bands in additively manufactured Ti-6Al-4V to measure small fatigue crack growth rates and equivalent initial damage sizes

IF 6.8 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-08-06 DOI:10.1016/j.ijfatigue.2025.109224

Christopher Bodger , Ben Main , Jireh Choi , Isaac Field , Simon Barter

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引用次数: 0

Abstract

Additive manufactured (AM) structural parts are being increasingly used within Defence platforms across all domains. In the air domain, it is necessary to correctly validate the durability and damage tolerance analysis tools used for certification and sustainment of AM parts. This is emphasised by MIL‑STD‑1530Dc1 and the United States Air Force structures bulletin EZ‑SB‑19‑001. One difficulty with this is that AM production processes are known to lead to multiple different types of discontinuities which can nucleate fatigue cracks. Depending on the size of these discontinuities, they have the potential to significantly reduce the fatigue life of the AM part.

The focus of this work is on demonstrating the viability of using marker bands to assist with obtaining both crack growth curves and small crack growth rate data and equivalent initial damage size distributions for AM Ti‑6Al-4V. This technique has previously been used successfully in many wrought aluminium components and full-scale tests. The work here showed that it was possible to design effective marker bands for AM Ti‑6Al‑4V. It is judged that further development of this technique would assist with correlating durability and damage tolerance tools used in the certification of this material.

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利用增材制造Ti-6Al-4V的标记带测量小疲劳裂纹扩展速率和等效初始损伤尺寸

增材制造（AM）结构部件越来越多地用于所有领域的国防平台。在航空领域，有必要正确验证用于增材制造零件认证和维护的耐久性和损伤容限分析工具。MIL - STD - 1530Dc1和美国空军结构公告EZ - SB - 19 - 001强调了这一点。这样做的一个困难是，已知增材制造过程会导致多种不同类型的不连续，这些不连续可能会形成疲劳裂纹。根据这些不连续性的大小，它们有可能显著降低增材制造部件的疲劳寿命。这项工作的重点是证明使用标记带来辅助获得AM Ti - 6Al-4V的裂纹扩展曲线和小裂纹扩展速率数据以及等效初始损伤尺寸分布的可行性。该技术以前已成功地用于许多锻造铝部件和全尺寸测试。这里的工作表明，可以为AM Ti - 6Al - 4V设计有效的标记带。据判断，该技术的进一步发展将有助于在该材料的认证中使用相关的耐久性和损伤容限工具。

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.