The extent to which residual stresses in AM components affects the performance in a fatigue crack growth (FCG) test is not fully understood. The aim of this project is to develop a model of the AM &nbsp;process for single edge notch samples of SLM 316L steel. This model will then be used to create a range of single edge notched bend and compact tension fracture mechanics samples for analysis, using varying construction methods. Finite element analysis methods will be used to analyse the residual stress relaxation at the crack tip in the models during simulated FCG tests, for comparison with existing test data. Experimental test results have shown&nbsp;that fatigue crack growth rates have decreased with crack length in a limited number of tests performed and the reasons for this not explained by metallurgy. A possible explanation is that that large residual stresses exist, which combine with the applied load to generate amplified stresses at the crack tip i.e. the total stress intrenisty factor K, is the sum of that from the applied load, Kp. &nbsp;and residual stress, Ks. These crack tip residual stresses are expected to decrease as the crack propagated through the sample, and hence even is the value of Kp increases with crack length the total value of K will decrease. In this work the residual stress field and Ks at the crack tip of a SLM fracture mecanics sample will be quantified as the crack grows. The influence of sample build orientation will also be examined

Prediction of Residual Stresses and Stress Intensity Factors in Fracture Mechanics Samples Manufactured by Laser Powder Bed Fusion

Paper Proceedings: https://asmedigitalcollection.asme.org/PVP/PVP2021/volume/85314

ASME 2021 Pressure Vessels & Piping Conference (PVP2021)

Supporting the need among researchers worldwide for additional online and multimedia content, ASME now offers the ASME Conference Video Collection. This platform will collect and provide long-term access to conference presentation videos, encompassing all technology areas within ASME's technical conference and events program. About 30,000-40,000 engineers across all mechanical engineering and related disciplines participate in ASME conferences each year. This includes authors of approximately 6,000 to 8,000 technical papers published by ASME, the majority of whom also submit video presentations for our virtual conferences. The video collection will be available as an add-on to existing product packages or as a separate subscription.