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Research Papers: Gas Turbines: Manufacturing, Materials, and Metallurgy

Fatigue and Strength Studies of Titanium 6Al–4V Fabricated by Direct Metal Laser Sintering

[+] Author and Article Information
Onome Scott-Emuakpor

Mem. ASME
Air Force Research Laboratory,
Aerospace Systems Directorate,
Wright-Patterson AFB, OH 45433
e-mail: onome.scott-emuakpor.1@us.af.mil

Casey Holycross

Mem. ASME
Air Force Research Laboratory,
Aerospace Systems Directorate,
Wright-Patterson AFB, OH 45433
e-mail: casey.holycross@us.af.mil

Tommy George

Mem. ASME
Air Force Research Laboratory,
Aerospace Systems Directorate,
Wright-Patterson AFB, OH 45433
e-mail: tommy.george@us.af.mil

Kevin Knapp

Air Force Research Laboratory,
Aerospace Systems Directorate,
Wright-Patterson AFB, OH 45433
e-mail: kevin.knapp.3@us.af.mil

Joseph Beck

Mem. ASME
Perceptive Engineering Analytics,
Lino Lakes, MN 55014
e-mail: joe_a_beck@yahoo.com

1Corresponding author.

Contributed by the Manufacturing Materials and Metallurgy Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received July 14, 2015; final manuscript received July 27, 2015; published online September 1, 2015. Editor: David Wisler. This material is declared a work of the U.S. Government and is not subject to copyright protection in the United States. Approved for public release; distribution is unlimited.

J. Eng. Gas Turbines Power 138(2), 022101 (Sep 01, 2015) (7 pages) Paper No: GTP-15-1306; doi: 10.1115/1.4031271 History: Received July 14, 2015

Vibratory bending fatigue behavior of titanium 6Al–4V plate specimens manufactured via direct metal laser sintering (DMLS), powder bed fusion additive manufacturing (AM), is assessed. Motivation for the work is based on unprecedented performance demands for sixth-generation gas turbine engine technology that requires complex, lightweight components. Due to cost, schedule, and feasibility limitations associated with conventional manufacturing, AM aims to address ubiquitous component concepts. Though AM has promise in the engine community, process controls necessary for consistent material properties remain an enigma. The following manuscript compares variability of DMLS fatigue and strength to cold-rolled data. Results show discrepancies between DMLS and cold-rolled for fatigue and microstructure characteristics.

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Figures

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Fig. 1

Vibration plate dimension (mm) and instrumentation locations

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Fig. 2

Vibratory analysis of the chordwise mode on a square plate: (a) von Mises stress and (b) mode shape

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Fig. 3

Dogbone cutout orientation is used to separate the multiple sentences

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Fig. 4

(a) DMLS build direction schematic and (b) top view of build structure

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Fig. 5

Point cloud mesh to CAD geometry comparison: (a) cold-rolled and (b) specimen #7 DMLS before milling

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Fig. 6

Forced response strain amplitude versus shaker head acceleration during sweeps: specimen #7

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Fig. 7

Forced response quality factor versus shaker head acceleration during sweeps: specimen #7

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Fig. 8

Ti 6Al–4V vibration bending fatigue life comparison

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Fig. 9

Comparison of ultimate tensile strength deviation from population per fatigue plate

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Fig. 10

Fractograph of DMLS specimen #1

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Fig. 11

SEM micrographs of Ti 6Al–4V: (a) DMLS and (b) cold-rolled

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