Fatigue Crack Growth Behavior of AlSi10Mg Material Produced by Direct Metal Laser Sintering Using S-Version Finite Element Method

• Published in: Journal of failure analysis and prevention Vol. 23; no. 2; pp. 601 - 608
• Main Authors: Chin, F. Y., Shaari, M. S., Takahashi, Akiyuki, Akramin, M. R. M., Urai, Sylvia
• Format: Journal Article
• Language: English
• Published: Materials Park Springer Nature B.V 01.04.2023
• Subjects: Crack closure; Crack propagation; Fatigue failure; Finite element analysis; Finite element method; Fracture mechanics; Laser sintering; Manufacturing; Materials failure; Stress intensity factors
• ISSN: 1547-7029; 1864-1245
• DOI: 10.1007/s11668-023-01643-6

The researchers are becoming more interested in additive manufacturing (AM). This technology has numerous advantages, particularly in the aerospace, medical and automotive industries. Due to the limited integrity of AM materials, there is a need to do research on this manufacturing technology. The primary concern of engineering applications is a material failure. The fatigue crack growth rate of the AM material, AlSi10Mg, is determined using the S-version finite element method (FEM). The global–local technique was used in the S-version FEM, which consists of two meshes: global and local. S-version FEM concentrated exclusively on the superimposed local crack. The stress intensity factor (SIF) of the crack is calculated using the virtual crack closure method. The SIF value is critical because it has an effect on crack growth. The Newman and Raju (Eng Fract Mech 11(4):817–829, 1979. https://doi.org/10.1016/0013-7944(79)90139-5) equation was used to validate the S-version FEM result. It demonstrates poor agreement due to computational and meshing limitations.