Very high cycle fatigue of laser powder bed fused Al-Cu-Mg-Ag-TiB2 (A20X) Alloy: Stress relief and aging treatments

•Unveiling VHCF behavior of laser powder bed fused A20X, a novel Al-Cu-Mg-Ag-TiB2 alloy.•Experimental revelation of asymptotic trend at 109 cycles.•Insights into defect/microstructure influence on enhanced fatigue performance.•Fisheye morphology observed, revealing internal crack-initiating site. Th...

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Published in:International journal of fatigue Vol. 183; p. 108281
Main Authors: Avateffazeli, Maryam, Shakil, Shawkat I., Behvar, Alireza, Attallah, Moataz M., Simsiriwong, Jutima, Tridello, Andrea, Paolino, Davide S., Haghshenas, Meysam
Format: Journal Article
Language:English
Published: Elsevier Ltd 01-06-2024
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Abstract •Unveiling VHCF behavior of laser powder bed fused A20X, a novel Al-Cu-Mg-Ag-TiB2 alloy.•Experimental revelation of asymptotic trend at 109 cycles.•Insights into defect/microstructure influence on enhanced fatigue performance.•Fisheye morphology observed, revealing internal crack-initiating site. This study presents a comprehensive exploration of the fatigue response in the very high cycle fatigue (VHCF) regime for an additively manufactured (i.e., laser powder bed fused) A20X aluminum alloy. Although the need for high-performance materials with exceptional fatigue qualities has increased dramatically, the VHCF behavior of Al-Cu-Mg-Ag-TiB2 (A20X) structures remains largely unknown. A series of ultrasonic fatigue tests were performed to assess the prolonged fatigue life of the A20X alloy (in the VHCF domain where the number of cycles to failure is beyond 10 million cycles). The VHCF response, assessed through ultrasonic fatigue testing, was investigated by examining the stress-life (S-N) curves in a statistical framework, the fatigue crack initiation and propagation behavior, and the fracture surfaces. An asymptotic trend was experimentally found at 109 cycles, with a stress amplitude of 110 MPa for stress-relieved (SR) and 125 MPa for artificially aged (T7) materials, indicating the presence of an endurance limit. Furthermore, fracture surfaces showed the typical fisheye morphology, with a fine granular area (FGA) containing an internal crack-initiating site. The findings of this paper can assist in optimizing fatigue and durability design allowable for applications for extended fatigue life in the VHCF domains.
AbstractList •Unveiling VHCF behavior of laser powder bed fused A20X, a novel Al-Cu-Mg-Ag-TiB2 alloy.•Experimental revelation of asymptotic trend at 109 cycles.•Insights into defect/microstructure influence on enhanced fatigue performance.•Fisheye morphology observed, revealing internal crack-initiating site. This study presents a comprehensive exploration of the fatigue response in the very high cycle fatigue (VHCF) regime for an additively manufactured (i.e., laser powder bed fused) A20X aluminum alloy. Although the need for high-performance materials with exceptional fatigue qualities has increased dramatically, the VHCF behavior of Al-Cu-Mg-Ag-TiB2 (A20X) structures remains largely unknown. A series of ultrasonic fatigue tests were performed to assess the prolonged fatigue life of the A20X alloy (in the VHCF domain where the number of cycles to failure is beyond 10 million cycles). The VHCF response, assessed through ultrasonic fatigue testing, was investigated by examining the stress-life (S-N) curves in a statistical framework, the fatigue crack initiation and propagation behavior, and the fracture surfaces. An asymptotic trend was experimentally found at 109 cycles, with a stress amplitude of 110 MPa for stress-relieved (SR) and 125 MPa for artificially aged (T7) materials, indicating the presence of an endurance limit. Furthermore, fracture surfaces showed the typical fisheye morphology, with a fine granular area (FGA) containing an internal crack-initiating site. The findings of this paper can assist in optimizing fatigue and durability design allowable for applications for extended fatigue life in the VHCF domains.
ArticleNumber 108281
Author Behvar, Alireza
Shakil, Shawkat I.
Haghshenas, Meysam
Simsiriwong, Jutima
Attallah, Moataz M.
Tridello, Andrea
Paolino, Davide S.
Avateffazeli, Maryam
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  givenname: Maryam
  surname: Avateffazeli
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  organization: Fatigue, Fracture, and Failure Laboratory (F3L), Department of Mechanical, Industrial, and Manufacturing Engineering (MIME), the University of Toledo, OH 43606, USA
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  givenname: Shawkat I.
  orcidid: 0000-0002-7062-6151
  surname: Shakil
  fullname: Shakil, Shawkat I.
  organization: Fatigue, Fracture, and Failure Laboratory (F3L), Department of Mechanical, Industrial, and Manufacturing Engineering (MIME), the University of Toledo, OH 43606, USA
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  givenname: Alireza
  orcidid: 0009-0007-0336-0406
  surname: Behvar
  fullname: Behvar, Alireza
  organization: Fatigue, Fracture, and Failure Laboratory (F3L), Department of Mechanical, Industrial, and Manufacturing Engineering (MIME), the University of Toledo, OH 43606, USA
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  givenname: Moataz M.
  orcidid: 0000-0002-7074-9522
  surname: Attallah
  fullname: Attallah, Moataz M.
  organization: School of Metallurgy and Materials, University of Birmingham, B15 2TT Birmingham, United Kingdom
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  givenname: Jutima
  surname: Simsiriwong
  fullname: Simsiriwong, Jutima
  organization: School of Engineering, University of North Florida, Jacksonville, FL 32224, USA
– sequence: 6
  givenname: Andrea
  orcidid: 0000-0003-3007-3377
  surname: Tridello
  fullname: Tridello, Andrea
  organization: Dipartimento di Ingegneria Meccanica e Aerospaziale, Politecnico di Torino, Corso Duca Degli Abruzzi 24, 10129 Torino, Italy
– sequence: 7
  givenname: Davide S.
  orcidid: 0000-0002-4231-4580
  surname: Paolino
  fullname: Paolino, Davide S.
  organization: Dipartimento di Ingegneria Meccanica e Aerospaziale, Politecnico di Torino, Corso Duca Degli Abruzzi 24, 10129 Torino, Italy
– sequence: 8
  givenname: Meysam
  surname: Haghshenas
  fullname: Haghshenas, Meysam
  email: meysam.haghshenas@utoledo.edu
  organization: Fatigue, Fracture, and Failure Laboratory (F3L), Department of Mechanical, Industrial, and Manufacturing Engineering (MIME), the University of Toledo, OH 43606, USA
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Keywords Very high cycle fatigue
LEVD
EBSD
ANOVA
EDS
S-N
DOF
SR
Al-Cu-Mg-Ag-TiB2
Laser powder bed fusion
FGA
T7
cdf
MS
A20X
FCC
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P-S-N
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AM
Ultrasonic fatigue
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LCF
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SEM
VHCF
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Snippet •Unveiling VHCF behavior of laser powder bed fused A20X, a novel Al-Cu-Mg-Ag-TiB2 alloy.•Experimental revelation of asymptotic trend at 109 cycles.•Insights...
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StartPage 108281
SubjectTerms A20X
Al-Cu-Mg-Ag-TiB2
Laser powder bed fusion
Ultrasonic fatigue
Very high cycle fatigue
Title Very high cycle fatigue of laser powder bed fused Al-Cu-Mg-Ag-TiB2 (A20X) Alloy: Stress relief and aging treatments
URI https://dx.doi.org/10.1016/j.ijfatigue.2024.108281
Volume 183
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