Fatigue Assessment of Wire and Arc Additively Manufactured Ti-6Al-4V

Wire and arc additively manufactured (WAAM) parts and structures often present internal defects, such as gas pores, and cause irregularities in the manufacturing process. In order to describe and assess the effect of internal defects in fatigue design, this research study investigates the fatigue strength of wire arc additive manufactured structures covering the influence of imperfections, particularly gas pores. Single pass WAAM structures are manufactured using titanium alloy Ti-6Al-4V and round fatigue, tensile specimen are extracted. Tensile tests and uniaxial fatigue tests with a load stress ratio of R = 0.1 were carried out, whereby fatigue test results are used for further assessments. An extensive fractographic and metallographic fracture surface analysis is utilized to characterize and measure crack-initiating defects. As surface pores as well as bulk pores are detected, a stress intensity equivalent Delta K-eqv transformation approach is presented in this study. Thereby, the defect size of the surface pore is transformed to an increased defect size, which is equivalent to a bulk pore. Subsequently, the fatigue strength assessment method by Tiryakioglu, commonly used for casting processes, is applied. For this method, a cumulative Gumbel extreme value distribution is utilized to statistically describe the defect size. The fitted distribution with modified data reveals a better agreement with the experimental data than unmodified. Additionally, the validation of the model shows that the usage of the Delta K modified data demonstrates better results, with a slight underestimation of up to about -7%, compared to unmodified data, with an overestimation of up to about 14%, comparing the number of load cycles until failure. Hence, the presented approach applying a stress intensity equivalent transformation of surface to bulk pores facilitates a sound fatigue strength assessment of WAAM Ti-6Al-4V structures.