Fatigue Behavior and Modeling of Additively Manufactured Ti-6Al-4V Including Interlayer Time Interval Effects

The effects of different cooling rates, as achieved by varying the interlayer time interval, on the fatigue behavior of additively manufactured Ti-6Al-4V specimens were investigated and modeled via a microstructure-sensitive fatigue model. Comparisons are made between two sets of specimens fabricated via Laser Engineered Net Shaping (LENS (TM)), with variance in interlayer time interval accomplished by depositing either one or two specimens per print operation. Fully reversed, strain-controlled fatigue tests were conducted, with fractography following specimen failure. A microstructure-sensitive fatigue model was calibrated to model the fatigue behavior of both sets of specimens and was found to be capable of correctly predicting the longer fatigue lives of the single-built specimens and the reduced scatter of the double-built specimens; all data points fell within the predicted upper and lower bounds of fatigue life. The time interval effects and the ability to be modeled are important to consider when producing test specimens that are smaller than the production part (i.e., property-performance relationships).