0
  • DE
  • EN
  • FR
  • International Database and Gallery of Structures

Advertisement

The effects of building position on surface and fatigue of DED-arc steel components

Author(s): ORCID




Medium: journal article
Language(s): English
Published in: Welding in the World, , n. 4, v. 67
Page(s): 859-872
DOI: 10.1007/s40194-022-01431-0
Abstract:

Abstract

Recently, additive manufacturing (AM) of structural metallic components is analyzed regarding its potential use by industry and research. Next to the development of manufacturing processes, the mechanical properties are under investigation today. One of the quality measures of metallic components is the surface topography. DED-arc processes (direct energy deposition) result in relatively coarse surfaces, characterized by a distinct waviness with wave amplitudes in the mm-range. This is enhanced when applying horizontal building position in comparison to vertical position. Next to increased waviness, the load-bearing net cross sections are reduced as well. The surface topography determines the fatigue life properties of metallic components. While stress raising surface effects are generally well understood and fatigue (Structures 31: 576–589, 2021) of welded metals is established well, the fatigue behaviour of additively manufactured components is less investigated yet. In order to define surface quality levels for DED-arc components, the effects of surface topography on mechanical performance need to be understood. This article presents the manufacturing of high strength steel test coupons by the DED-arc process. The process parameters were varied with regard to the building position and different levels of surface quality were generated. The surfaces of different specimens were characterized and fatigue tests were conducted. The results were used to derive the surface influence on both, the effective load-bearing wall thickness and notch effects induced by the layer-by-layer building approach. A correlation between building position, surface waviness and fatigue strength was proven. In general, higher waviness resulted in reduced effective wall thickness and lowered fatigue strength. A difference in fatigue strength at 2 million load cycles of 20 to 30% was proven when printing in different building positions. The surface effect can be captured in the design concept when applying the effective notch stress approach with an averaging length of of ρ* = 0.4 mm. The fatigue strength is describable by a design S–N curve FAT160 and a k-value of 4.

Structurae cannot make the full text of this publication available at this time. The full text can be accessed through the publisher via the DOI: 10.1007/s40194-022-01431-0.
  • About this
    data sheet
  • Reference-ID
    10776879
  • Published on:
    12/05/2024
  • Last updated on:
    12/05/2024
 
Structurae cooperates with
International Association for Bridge and Structural Engineering (IABSE)
e-mosty Magazine
e-BrIM Magazine