Damage tolerant design of additively manufactured metallic components subjected to cyclic loading: State of the art and challenges

Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the discussion at an international...

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Published inProgress in materials science Vol. 121; p. 100786
Main Authors Zerbst, Uwe, Bruno, Giovanni, Buffière, Jean-Yves, Wegener, Thomas, Niendorf, Thomas, Wu, Tao, Zhang, Xiang, Kashaev, Nikolai, Meneghetti, Giovanni, Hrabe, Nik, Madia, Mauro, Werner, Tiago, Hilgenberg, Kai, Koukolíková, Martina, Procházka, Radek, Džugan, Jan, Möller, Benjamin, Beretta, Stefano, Evans, Alexander, Wagener, Rainer, Schnabel, Kai
Format Journal Article
LanguageEnglish
Published England Elsevier Ltd 01.08.2021
Elsevier BV
Subjects
Additive manufacturing
Component assessment
Crack propagation
Criteria
Crystal defects
Cyclic loads
Damage tolerance
Defects
Fatigue failure
Fatigue life
Fatigue loading
Finite element method
Grain size
Materials science
Microstructure
New technology
Nondestructive testing
Powder beds
Process parameters
Residual stress
Residual stresses
Damage tolerance
Component assessment
Additive manufacturing
Residual stresses
Fatigue loading
Defects
damage tolerance
component assessment
defects
fatigue loading
residual stresses
Online AccessGet full text
ISSN0079-6425
1873-2208
DOI10.1016/j.pmatsci.2021.100786

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Abstract Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the discussion at an international workshop on the topic. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials:-Criteria for damage tolerant component design;-Criteria for the determination of fatigue and fracture properties;-Strategies for the determination of the fatigue life in dependence of different manufacturing conditions;-Methods for the quantitative characterization of microstructure and defects;-Methods for the determination of residual stresses;-Effect of the defects and the residual stresses on the fatigue life and behaviour.We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. finite element modeling) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.
AbstractList Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the workshop discussions. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials: Criteria for damage tolerant component design;Criteria for the determination of fatigue and fracture properties;Strategies for the determination of the fatigue life in dependence of different manufacturing conditions;Methods for the quantitative characterization of microstructure and defects;Methods for the determination of residual stresses;Effect of the defects and the residual stresses on the fatigue life and behaviour. We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. FEM) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the workshop discussions. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials: Criteria for damage tolerant component design;Criteria for the determination of fatigue and fracture properties;Strategies for the determination of the fatigue life in dependence of different manufacturing conditions;Methods for the quantitative characterization of microstructure and defects;Methods for the determination of residual stresses;Effect of the defects and the residual stresses on the fatigue life and behaviour. We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. FEM) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.
Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the discussion at an international workshop on the topic. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials:-Criteria for damage tolerant component design;-Criteria for the determination of fatigue and fracture properties;-Strategies for the determination of the fatigue life in dependence of different manufacturing conditions;-Methods for the quantitative characterization of microstructure and defects;-Methods for the determination of residual stresses;-Effect of the defects and the residual stresses on the fatigue life and behaviour.We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. finite element modeling) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.
Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the workshop discussions. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials: Criteria for damage tolerant component design;Criteria for the determination of fatigue and fracture properties;Strategies for the determination of the fatigue life in dependence of different manufacturing conditions;Methods for the quantitative characterization of microstructure and defects;Methods for the determination of residual stresses;Effect of the defects and the residual stresses on the fatigue life and behaviour. We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. FEM) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.
Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the discussion at an international workshop on the topic. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials: Criteria for damage tolerant component design; Criteria for the determination of fatigue and fracture properties; Strategies for the determination of the fatigue life in dependence of different manufacturing conditions; Methods for the quantitative characterization of microstructure and defects; Methods for the determination of residual stresses; Effect of the defects and the residual stresses on the fatigue life and behaviour. We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. finite element modeling) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.
Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant challenges currently facing the use of these new technologies. This article presents a thorough overview of the workshop discussions. It aims to provide a review of the parameters affecting the damage tolerance of parts produced by additive manufacturing (shortly, AM parts) with special emphasis on the process parameters intrinsic to the AM technologies, the resulting defects and the residual stresses. Based on these aspects, basic concepts are reviewed and critically discussed specifically for AM materials: Criteria for damage tolerant component design; Criteria for the determination of fatigue and fracture properties; Strategies for the determination of the fatigue life in dependence of different manufacturing conditions; Methods for the quantitative characterization of microstructure and defects; Methods for the determination of residual stresses; Effect of the defects and the residual stresses on the fatigue life and behaviour. We see that many of the classic concepts need to be expanded in order to fit with the particular microstructure (grain size and shape, crystal texture) and defect distribution (spatial arrangement, size, shape, amount) present in AM (in particular laser powder bed fusion). For instance, 3D characterization of defects becomes essential, since the defect shapes in AM are diverse and impact the fatigue life in a different way than in the case of conventionally produced components. Such new concepts have immediate consequence on the way one should tackle the determination of the fatigue life of AM parts; for instance, since a classification of defects and a quantification of the tolerable shapes and sizes is still missing, a new strategy must be defined, whereby theoretical calculations (e.g. FEM) allow determining the maximum tolerable defect size, and non-destructive testing (NDT) techniques are required to detect whether such defects are indeed present in the component. Such examples show how component design, damage and failure criteria, and characterization (and/or NDT) become for AM parts fully interlinked. We conclude that the homogenization of these fields represents the current challenge for the engineer and the materials scientist.
ArticleNumber 100786
Author Madia, Mauro
Schnabel, Kai
Evans, Alexander
Meneghetti, Giovanni
Hilgenberg, Kai
Kashaev, Nikolai
Hrabe, Nik
Džugan, Jan
Koukolíková, Martina
Zhang, Xiang
Werner, Tiago
Bruno, Giovanni
Wegener, Thomas
Wu, Tao
Procházka, Radek
Buffière, Jean-Yves
Zerbst, Uwe
Beretta, Stefano
Wagener, Rainer
Möller, Benjamin
Niendorf, Thomas
AuthorAffiliation 6) University of Padova, via Venezia, 1, I-35131 Padova, Italy
1) Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
8) COMTES FHT, Průmyslová 995, 334 41 Dobřany, Czech Republic
3) University Kassel, Material Science, Sophie-Henschel-Haus 3, D-34125 Kassel, Germany
4) Coventry University, Priory Street, CV1 5FB Coventry. U.K
7) National Institute of Standards and Technology (NIST) 325 Broadway, MS-647 Boulder CO 80305, U.S.A. (The part of Nik Hrabe is an official contribution of NIST and is not subject to the copyright of the United states.
5) Helmholtz-Zentrum Geesthacht, Max-Plank-Str. 1, D-21502 Geesthacht, Germany
2) INSA-Lyon, F-69621 Villeurbanne, France
9) Fraunhofer-Institut für Betriebsfestigkeit (LBF), Bartningstr. 47, D-64298 Darmstadt, Germany
10) Politecnico di Milano, via La Masa 1, 20156 Milan, Italy
AuthorAffiliation_xml – name: 3) University Kassel, Material Science, Sophie-Henschel-Haus 3, D-34125 Kassel, Germany
– name: 9) Fraunhofer-Institut für Betriebsfestigkeit (LBF), Bartningstr. 47, D-64298 Darmstadt, Germany
– name: 4) Coventry University, Priory Street, CV1 5FB Coventry. U.K
– name: 7) National Institute of Standards and Technology (NIST) 325 Broadway, MS-647 Boulder CO 80305, U.S.A. (The part of Nik Hrabe is an official contribution of NIST and is not subject to the copyright of the United states.
– name: 10) Politecnico di Milano, via La Masa 1, 20156 Milan, Italy
– name: 5) Helmholtz-Zentrum Geesthacht, Max-Plank-Str. 1, D-21502 Geesthacht, Germany
– name: 1) Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
– name: 2) INSA-Lyon, F-69621 Villeurbanne, France
– name: 8) COMTES FHT, Průmyslová 995, 334 41 Dobřany, Czech Republic
– name: 6) University of Padova, via Venezia, 1, I-35131 Padova, Italy
Author_xml – sequence: 1
  givenname: Uwe
  surname: Zerbst
  fullname: Zerbst, Uwe
  email: uwe.zerbst@bam.de
  organization: Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
– sequence: 2
  givenname: Giovanni
  surname: Bruno
  fullname: Bruno, Giovanni
  email: giovanni.bruno@bam.de
  organization: Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
– sequence: 3
  givenname: Jean-Yves
  surname: Buffière
  fullname: Buffière, Jean-Yves
  organization: INSA-Lyon, F-69621 Villeurbanne, France
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  givenname: Thomas
  surname: Wegener
  fullname: Wegener, Thomas
  organization: University of Kassel, Institute of Materials Engineering - Metallic Materials, Mönchebergstraße 3, D-34125 Kassel, Germany
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  surname: Niendorf
  fullname: Niendorf, Thomas
  organization: University of Kassel, Institute of Materials Engineering - Metallic Materials, Mönchebergstraße 3, D-34125 Kassel, Germany
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  surname: Zhang
  fullname: Zhang, Xiang
  organization: Coventry University, Priory Street, CV1 5FB Coventry, UK
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  surname: Kashaev
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  surname: Meneghetti
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  givenname: Mauro
  surname: Madia
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  organization: Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
– sequence: 12
  givenname: Tiago
  surname: Werner
  fullname: Werner, Tiago
  organization: Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
– sequence: 13
  givenname: Kai
  surname: Hilgenberg
  fullname: Hilgenberg, Kai
  organization: Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
– sequence: 14
  givenname: Martina
  surname: Koukolíková
  fullname: Koukolíková, Martina
  organization: COMTES FHT, Průmyslová 995, 334 41 Dobřany, Czech Republic
– sequence: 15
  givenname: Radek
  surname: Procházka
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  surname: Džugan
  fullname: Džugan, Jan
  organization: COMTES FHT, Průmyslová 995, 334 41 Dobřany, Czech Republic
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  givenname: Benjamin
  surname: Möller
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  organization: Fraunhofer-Institut für Betriebsfestigkeit (LBF), Bartningstr. 47, D-64298 Darmstadt, Germany
– sequence: 18
  givenname: Stefano
  surname: Beretta
  fullname: Beretta, Stefano
  organization: Politecnico di Milano, via La Masa 1, 20156 Milan, Italy
– sequence: 19
  givenname: Alexander
  surname: Evans
  fullname: Evans, Alexander
  organization: Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, D-12205 Berlin, Germany
– sequence: 20
  givenname: Rainer
  surname: Wagener
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  organization: Fraunhofer-Institut für Betriebsfestigkeit (LBF), Bartningstr. 47, D-64298 Darmstadt, Germany
– sequence: 21
  givenname: Kai
  surname: Schnabel
  fullname: Schnabel, Kai
  organization: Fraunhofer-Institut für Betriebsfestigkeit (LBF), Bartningstr. 47, D-64298 Darmstadt, Germany
BackLink https://www.ncbi.nlm.nih.gov/pubmed/34433989$$D View this record in MEDLINE/PubMed
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IsDoiOpenAccess false
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Keywords Damage tolerance
Component assessment
Additive manufacturing
Residual stresses
Fatigue loading
Defects
damage tolerance
component assessment
defects
fatigue loading
residual stresses
Language English
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PublicationTitle Progress in materials science
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Snippet Undoubtedly, a better understanding and the further development of approaches for damage tolerant component design of AM parts are among the most significant...
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SubjectTerms Additive manufacturing
Component assessment
Crack propagation
Criteria
Crystal defects
Cyclic loads
Damage tolerance
Defects
Fatigue failure
Fatigue life
Fatigue loading
Finite element method
Grain size
Materials science
Microstructure
New technology
Nondestructive testing
Powder beds
Process parameters
Residual stress
Residual stresses
Title Damage tolerant design of additively manufactured metallic components subjected to cyclic loading: State of the art and challenges
URI https://dx.doi.org/10.1016/j.pmatsci.2021.100786
https://www.ncbi.nlm.nih.gov/pubmed/34433989
https://www.proquest.com/docview/2559476218
https://www.proquest.com/docview/2564950747
https://pubmed.ncbi.nlm.nih.gov/PMC8383831
Volume 121
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