Establishing an Acceptance Criteria for Assessing Fatigue of Additive Repair Processes

2021 ◽  
Author(s):  
Onome Scott-Emuakpor ◽  
Luke Sheridan ◽  
Joseph Beck ◽  
Brian Runyon ◽  
Tommy George
Keyword(s):  
Regression Analysis ◽  
Additive Manufacturing ◽  
Energy Deposition ◽  
High Cycle Fatigue ◽  
Fatigue Behavior ◽  
Cycle Fatigue ◽  
Turbine Engine ◽  
Predicted Values ◽  
Directed Energy ◽  
Repair Techniques

Abstract Criteria for assessing high cycle fatigue (HCF) capability is important for transitioning additive repair technologies to turbine engine applications. By studying the fatigue results of two laser directed energy deposition additive manufacturing repairs on airfoil representative Titanium 6Al-4V coupons, acceptable HCF results for repairs can be determined by observing the confidence in predicted values and the reliability of the empirical data compared to baseline results. The following document details the steps and philosophies behind fabricating coupons that capture the repair capability. Furthermore, regression analysis as well as investigations of dataset distribution, fractography, and microscopy are necessary for instilling confidence in the understanding of repair fatigue behavior. The findings in this work provide a decision gate with quantifiable metrics for advancing novel repair techniques.

Establishing an Acceptance Criteria for Assessing Fatigue of Additive Repair Processes

2021 ◽  
Author(s):  
Onome Scott-Emuakpor ◽  
Luke Sheridan ◽  
Joseph Beck ◽  
Brian Runyon ◽  
Tommy George
Keyword(s):  
Regression Analysis ◽  
Additive Manufacturing ◽  
Energy Deposition ◽  
High Cycle Fatigue ◽  
Fatigue Behavior ◽  
Cycle Fatigue ◽  
Turbine Engine ◽  
Predicted Values ◽  
Directed Energy ◽  
Repair Techniques

Abstract Criteria for assessing high cycle fatigue (HCF) capability is important for transitioning additive repair technologies to turbine engine applications. By studying the fatigue results of two laser directed energy deposition additive manufacturing repairs on airfoil representative Titanium 6Al-4V coupons, acceptable HCF results for repairs can be determined by observing the confidence in predicted values and the reliability of the empirical data compared to baseline results. The following document details the steps and philosophies behind fabricating coupons that capture the repair capability. Furthermore, regression analysis as well as investigations of dataset distribution, fractography, and microscopy are necessary for instilling confidence in the understanding of repair fatigue behavior. The findings in this work provide a decision gate with quantifiable metrics for advancing novel repair techniques.

scholarly journals High Frequency Vibration Fatigue Behavior of Ti6Al4V Fabricated by Wire-Fed Electron Beam Additive Manufacturing Technology

2020 ◽  
Vol 2020 ◽  
pp. 1-14 ◽  
Author(s):  
P. Wanjara ◽  
J. Gholipour ◽  
E. Watanabe ◽  
K. Watanabe ◽  
T. Sugino ◽  
...  
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Gas Turbine ◽  
High Cycle Fatigue ◽  
Fatigue Behavior ◽  
Gas Turbine Engine ◽  
Cycle Fatigue ◽  
Turbine Engine ◽  
Fatigue Data ◽  
The Impact

Following foreign object damage (FOD), a decision to repair components using novel additive manufacturing (AM) technologies has good potential to enable cost-effective and efficient solutions for aircraft gas turbine engine maintenance. To implement any new technology in the gas turbine remanufacturing world, the performance of the repair must be developed and understood through careful consideration of the impact of service life-limiting factors on the structural integrity of the component. In modern gas turbine engines, high cycle fatigue (HCF) is one of the greatest causes of component failure. However, conventional uniaxial fatigue data is inadequate in representing the predominant HCF failure mode of gas turbine components that is caused by vibration. In this study, the vibratory fatigue behavior of Ti6Al4V deposited using wire-fed electron beam additive manufacturing (EBAM) was examined with the motivation of developing an advanced repair solution for fatigue critical cold-section parts, such as blades and vanes, in gas turbine engine applications. High cycle fatigue data, generated using a combination of step-testing procedure and vibration (resonance) fatigue testing, was analyzed through Dixon–Mood statistics to calculate the endurance limits and standard deviations of the EBAM and wrought Ti6Al4V materials. Also plots of stress (S) against the number of cycles to failure (N) were obtained for both materials. The average fatigue endurance limit of the EBAM Ti6Al4V was determined to be greater than the wrought counterpart. But the lower limit (95% reliability) of 426 MPa for the EBAM Ti6Al4V was lower than the value of 497 MPa determined for wrought Ti6Al4V and was attributed to the slightly higher data scatter–as reflected by the higher standard deviation–of the former material.

scholarly journals Fatigue Assessment of Inconel 625 Produced by Directed Energy Deposition from Miniaturized Specimens

Metals ◽  
2022 ◽  
Vol 12 (1) ◽  
pp. 156
Author(s):  
Felipe Klein Fiorentin ◽  
Duarte Maciel ◽  
Jorge Gil ◽  
Miguel Figueiredo ◽  
Filippo Berto ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Energy Deposition ◽  
High Cycle Fatigue ◽  
Fatigue Performance ◽  
Fatigue Properties ◽  
Inconel 625 ◽  
Cycle Fatigue ◽  
Directed Energy Deposition ◽  
Metallic Additive ◽  
Directed Energy

In recent years, the industrial application of Inconel 625 has grown significantly. This material is a nickel-base alloy, which is well known for its chemical resistance and mechanical properties, especially in high-temperature environments. The fatigue performance of parts produced via Metallic Additive Manufacturing (MAM) heavily rely on their manufacturing parameters. Therefore, it is important to characterize the properties of alloys produced by a given set of parameters. The present work proposes a methodology for characterization of the mechanical properties of MAM parts, including the material production parametrization by Laser Directed Energy Deposition (DED). The methodology consists of the testing of miniaturized specimens, after their production in DED, supported by a numerical model developed and validated by experimental data for stress calculation. An extensive mechanical characterization, with emphasis on high-cycle fatigue, of Inconel 625 produced via DED is herein discussed. The results obtained using miniaturized specimens were in good agreement with standard-sized specimens, therefore validating the applied methodology even in the case of some plastic effects. Regarding the high-cycle fatigue properties, the samples produced via DED presented good fatigue performance, comparable with other competing Metallic Additive Manufactured (MAMed) and conventionally manufactured materials.

scholarly journals Influence of warm caliber rolling on tensile response and high cycle fatigue behavior of hypereutectoid steel

2021 ◽  
Vol 10 ◽  
pp. 205-215
Author(s):  
Kyu-Sik Kim ◽  
Young-Kyun Kim ◽  
Hyeon-Jin Kim ◽  
Jeoung Han Kim ◽  
Kee-Ahn Lee
Keyword(s):  
High Cycle Fatigue ◽  
Fatigue Behavior ◽  
Cycle Fatigue ◽  
Hypereutectoid Steel ◽  
Tensile Response

scholarly journals Directed energy deposition additive manufacturing of functionally graded Al-W composites

2021 ◽  
Vol 39 ◽  
pp. 101845
Author(s):  
J.P. Kelly ◽  
J.W. Elmer ◽  
F.J. Ryerson ◽  
J.R.I. Lee ◽  
J.J. Haslam
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Functionally Graded ◽  
Directed Energy Deposition ◽  
Directed Energy
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