Numerical simulation of surface roughness effects on low-cycle fatigue properties of additively manufactured titanium alloys

Additive manufacturing (AM) is a complex process involving a multiscal physical phenomena (solid–liquid-gas), often resulting in poor surface quality. Although surface treatments such as polishing or chemical treatment can improve surface quality, localized sub-grain stress concentrations induced by surface roughness anomalies are still easily formed, which can lead to the reduction and dispersion of fatigue properties in AM alloys. In this study, a numerical simulation model is proposed to study the association between surface roughness and fatigue properties of AM alloys. Based on the continuum damage mechanics modeling framework, an idealised grain/grain boundary model is generated by employing the Voronoi tessellation meshing technology. The numerical simulations are performed for the model with different surface geometric states. The correlation between surface roughness geometric features and fatigue properties is analyzed and discussed. A parameter “G” which comprehensively considers the influence of the maximum surface height (Rz) and correlation length (Lcor) is proposed to quantify the influence of surface roughness geometric features on the fatigue properties of AM alloys. This finding can be of great significance in improving the surface integrity of components to increase service life. © 2024 Elsevier Ltd