Very High Cycle Fatigue (VHCF) Assessment of Laser Additive Manufactured (LAM) AlSi12 Alloy

Selective laser melting (SLM) is a laser additive manufacturing process where parts are additively manufactured using powder material with the aid of laser energy. Threedimensional CAD model is provided as an input to the SLM machine, which scans the geometry after slicing the geometry into 2D layers. The laser energy selectively melts the powder particles at the desired location of the component to be manufactured. The unique manufacturing capability of SLM process makes it suitable for aerospace, automotive and biomedical applications. Several alloys like aluminum, titanium, steel and nickelbased alloys have been processed by SLM technique. Although the fatigue strength diminishes for SLM processed materials in the “as-built” condition due to the process-inherent surface roughness, fatigue performance after post-processing is suitable for many applications in the aviation and medical industry. Contrary to the previous assumption that the materials do not fail under fatigue if the applied stress is below the so-called fatigue limit; with the availability of the novel very high cycle fatigue (VHCF) testing techniques, it has been found that materials do fail under fatigue loading even when the stresses are below the conventional fatigue limit, suggesting the nonexistence of such a limit. Some alloys of both lattice types (bcc and fcc) show a change in crack initiation site from surface to subsurface in a region from HCF to VHCF.

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Application News
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Material Testing, Fatigue Testing
Materials/Automotive, Additive Manufacturing, USF-2000A Ultrasonic Gigacycle Fatigue Testing System
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