Fatigue behaviour of wire arc additively manufactured sheet material

authored by: Cheng Huang, Lingzhen Li, Niels Pichler, Elyas Ghafoori, Leroy Gardner
Abstract: Wire arc additive manufacturing (WAAM) is a metal 3D printing technique well recognised in the construction sector for its high efficiency, cost-effectiveness and flexibility in build scales. However, there remains a lack of fundamental data on the structural performance of WAAM elements, especially regarding their fatigue behaviour. A comprehensive experimental study into the fatigue behaviour of WAAM steel plates has therefore been undertaken and is reported herein. Following geometric and mechanical characterisation, a series of WAAM coupons was tested under uniaxial high-cycle fatigue loading. A total of 75 fatigue tests on both as-built and machined coupons, covering various stress ranges and stress ratios, have been conducted. The fatigue test results were analysed using constant life diagrams (CLDs) and S-N (stress-life) diagrams. The CLDs revealed that the fatigue strength of the as-built WAAM steel was relatively insensitive to the different stress ratios. The S-N diagrams showed that the surface undulations resulted in a reduction of about 35% in the fatigue endurance limit for the as-built WAAM material relative to the machined material, and a reduction of about 60% in fatigue life under the same load level. Preliminary S-N curves were also proposed for the WAAM steel.
Organisation(s): Institute of Steel Construction
External Organisation(s): Imperial College London
Swiss Federal Laboratories for Material Science and Technology (EMPA)
ETH Zurich
Type: Conference article
Journal: Procedia Structural Integrity
Volume: 57
Pages: 42-52
No. of pages: 11
ISSN: 2452-3216
Publication date: 2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Civil and Structural Engineering, General Materials Science, Mechanics of Materials, Mechanical Engineering
Electronic version(s): https://doi.org/10.1016/j.prostr.2024.03.006 (Access: Open)

BibTeX

@article{99fa3366976b49568bc9c8157f17cd7f,
title = "Fatigue behaviour of wire arc additively manufactured sheet material",
abstract = "Wire arc additive manufacturing (WAAM) is a metal 3D printing technique well recognised in the construction sector for its high efficiency, cost-effectiveness and flexibility in build scales. However, there remains a lack of fundamental data on the structural performance of WAAM elements, especially regarding their fatigue behaviour. A comprehensive experimental study into the fatigue behaviour of WAAM steel plates has therefore been undertaken and is reported herein. Following geometric and mechanical characterisation, a series of WAAM coupons was tested under uniaxial high-cycle fatigue loading. A total of 75 fatigue tests on both as-built and machined coupons, covering various stress ranges and stress ratios, have been conducted. The fatigue test results were analysed using constant life diagrams (CLDs) and S-N (stress-life) diagrams. The CLDs revealed that the fatigue strength of the as-built WAAM steel was relatively insensitive to the different stress ratios. The S-N diagrams showed that the surface undulations resulted in a reduction of about 35% in the fatigue endurance limit for the as-built WAAM material relative to the machined material, and a reduction of about 60% in fatigue life under the same load level. Preliminary S-N curves were also proposed for the WAAM steel.",
keywords = "Experiments, Fatigue life, Geometric variability, Metal 3D printing, Wire arc additive manufacturing",
author = "Cheng Huang and Lingzhen Li and Niels Pichler and Elyas Ghafoori and Leroy Gardner",
note = "Publisher Copyright: {\textcopyright} 2024 The Authors. Published by Elsevier B.V.; 10th International Conference on Fatigue Design, FatDes 2023 ; Conference date: 29-11-2023 Through 30-11-2023",
year = "2024",
doi = "10.1016/j.prostr.2024.03.006",
language = "English",
volume = "57",
pages = "42--52",
journal = "Procedia Structural Integrity",
issn = "2452-3216",
publisher = "Elsevier BV",
}