TENSILE AND HIGH CYCLE FATIGUE PROPERTIES OF ANNEALED TI6AL4V (ELI) SPECIMENS PRODUCED BY DIRECT METAL LASER SINTERING

The tensile and high cycle fatigue (HCF) properties of high temperature annealed (HTA) direct metal laser sintered (DMLS) Ti6Al4V extra low interstitial (ELI) machined and polished specimens were investigated. The HTA heat treatment of the specimens resulted in the nucleation and growth of the alpha and beta grains from the acicular alpha' martensite grains, improving their elongation to failure. The specimens were micro-CT scanned in an attempt to relate the pores in the specimens to their fatigue properties. The micro-CT pore information from suspected crack initiation pores on the surfaces of eventual fracture was used to calculate the stress intensity factors, which correlated well with the decreasing cycles to failure of the fatigue test specimens for all three build directions. Three representative specimens were analysed, and the 'killer pore' was identified in each micro-CT scan and fractograph, all of which were proximal to the surface of the specimen.