SIM-AM 2025

Macroscopically modeling fatigue behavior of additively manufactured metals: pore-defect informed phase-field model

  • Yi, Min (Nanjing University of Aeronautics and Astrona)

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Fatigue crack growth (FCG) behavior and fatigue life of additively manufactured (AM) materials are highly sensitive to AM-induced pore defects, thus challenging the traditional fatigue models. A model customized for predicting fatigue/fracture behavior of AM materials is indispensable. Here we propose a pore-defect informed phase-field model (PFM) for the macroscopic modeling of fatigue crack initiation (FCI), FCG, and fatigue life of AM metals. The macroscopic PFM integrates pore-defect fatigue (PDF) model of AM metals, local stress–strain approach and cumulative fatigue damage theory. The PDF model correlates AM pore features (i.e., size, location, and morphology) with fatigue life and its parameters can be readily determined by fatigue test of standard specimens of AM metals. Our PFM is confirmed to be capable of predicting both S(E)–N curves and Paris’ law of AM metallic (nickel base superalloy Hastelloy X, titanium alloy TC4 and TC17) specimens over low- and high-cycle fatigue regimes, and the predictions are found to agree well with experiments. For a simulated compressor blade fabricated by laser AM, our three-dimensional PFM simulations of FCI and FCG behaviors could correctly predict the critical crack length and fatigue limit, which accord with experimental results obtained by X-ray computer tomography and vibration fatigue test. The pore-defect informed PFM framework here could provide a practicable toolkit for the rapid evaluation of fatigue life of AM components, as well as for the computational prediction and design of fatigue-resistant AM components.