Fatigue and damage tolerance performance of additively-manufactured titanium alloys for structural application: A comprehensive review

IF 31.6 1区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials Science and Engineering: R: Reports Pub Date : 2025-10-25 DOI:10.1016/j.mser.2025.101135

Jianwen Liu , Kai Zhang , Michael J. Bermingham , Hamish L. Fraser , Peter Hodgson , Martin Heilmaier , Alberto Boretti , Yuman Zhu , Aijun Huang

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Abstract

Titanium (Ti) alloys have emerged as one of the most sought-after metallic materials for additive manufacturing (AM). This originates from the unparalleled synergy of AM's capability to produce intricate geometries and the superior mechanical properties and corrosion resistance inherent to Ti alloys. Despite these benefits, AM Ti alloys continue to face persistent challenges that hinder their in-service reliability and broader adoption. Unlike conventionally manufacturing, AM introduces unique microstructural features such as non-uniform residual stresses and inhomogeneous grain structures, which often result in pronounced variability in material properties. Crucially, this variability underscores an urgent need for thorough performance evaluation of AM-produced parts, especially for critical structural applications where safety and durability are paramount. Previous reviews have broadly addressed AM Ti alloys' static properties and general processing challenges. In contrast, this review takes a comprehensive approach to examine the dynamic performance aspects—specifically, fatigue and damage tolerance—which remain insufficiently summarized yet vital for real-world applications. It deepens into the underlying mechanisms governing these properties, emphasizing the influence of key defects (e.g., porosity, segregation) as well as microstructural characteristics such as grain morphology and residual stresses. Additionally, this work expands the discussion to assess the behavior of AM Ti alloys under extreme environmental conditions (high-temperature and cryogenic operations), which are increasing demand in the automotive and energy sectors. By providing a detailed evaluation of these critical aspects, this review aims to bridge existing knowledge gaps, offering actionable insights to refine AM Ti alloy processing and enhance their structural reliability for demanding applications.

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结构用增材钛合金的疲劳和损伤容限性能综述

钛（Ti）合金已成为增材制造（AM）中最受欢迎的金属材料之一。这源于AM生产复杂几何形状的能力以及钛合金固有的优越机械性能和耐腐蚀性的无与伦比的协同作用。尽管有这些优点，AM钛合金仍然面临着持续的挑战，阻碍了它们的使用可靠性和更广泛的应用。与传统制造不同，增材制造引入了独特的微观结构特征，如不均匀的残余应力和不均匀的晶粒结构，这通常会导致材料性能的显著变化。至关重要的是，这种可变性强调了对am生产部件进行全面性能评估的迫切需要，特别是对于安全性和耐久性至关重要的关键结构应用。以前的评论广泛地讨论了AM Ti合金的静态性能和一般的加工挑战。相比之下，这篇综述采用了一种全面的方法来研究动态性能方面，特别是疲劳和损伤容限，这些方面仍然没有得到充分的总结，但对实际应用至关重要。它深入到控制这些性能的潜在机制，强调关键缺陷（例如，孔隙度，偏析）以及微观结构特征（如晶粒形态和残余应力）的影响。此外，这项工作扩大了讨论范围，以评估AM Ti合金在极端环境条件下（高温和低温操作）的行为，这在汽车和能源部门的需求不断增加。通过对这些关键方面的详细评估，本综述旨在弥合现有的知识差距，提供可操作的见解，以改进AM钛合金的加工，并提高其结构可靠性，以满足苛刻的应用。

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来源期刊

Materials Science and Engineering: R: Reports 工程技术-材料科学：综合

CiteScore

60.50

自引率

0.30%

发文量

审稿时长

34 days

期刊介绍： Materials Science & Engineering R: Reports is a journal that covers a wide range of topics in the field of materials science and engineering. It publishes both experimental and theoretical research papers, providing background information and critical assessments on various topics. The journal aims to publish high-quality and novel research papers and reviews. The subject areas covered by the journal include Materials Science (General), Electronic Materials, Optical Materials, and Magnetic Materials. In addition to regular issues, the journal also publishes special issues on key themes in the field of materials science, including Energy Materials, Materials for Health, Materials Discovery, Innovation for High Value Manufacturing, and Sustainable Materials development.