PSI - Issue 53

ScienceDirect Structural Integrity Procedia 00 (2023) 000–000 Structural Integrity Procedia 00 (2023) 000–000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 53 (2024) 190–202

© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons Abstract Within the framework of multi-functional and multi-material additive manufacturing, hollow structures made of AA6063 (AlMgSi0,5) were manufactured by wire arc additive manufacturing (WAAM). These form the basis for a motorcycle handlebar, which has to resist 3-dimensional bending fatigue load cases with respect to the mid axis of the handlebar: lifting the motorbike and braking. The latter one was chosen for an experimental and numerical fatigue assessment. For the experimental analysis, axial bending fatigue testing was chosen to derive Wöhler curves for the bending moment using the Maximum Likelihood Estimation. On the basis of 3d scans of the experimentally investigated WAAM hollow structures, finite element models were derived. From the load simulations of these models crack initiation locations were predicted and a fatigue assessment based on Von Mises equivalent stresses was carried out, resulting in a stress concentration factor of 2. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license ( https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons Keywords: WAAM; aluminum; defect; fatigue assessment; numerical analysis Development and fatigue assessment of wire arc additively manufactured hollow structures made of AA6063 as a basis for functional integrated sections applied to a motorcycle handlebar Benjamin Möller a *, Marvin Kiel a , Rainer Wagener a , Enrico Taliani a , Richard Kordaß b , Michael Schramm b , Rudolf Gradinger c a Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany b EDAG Engineering GmbH, Kreuzberger Ring 40, 65205 Wiesbaden, Germany c AIT Austrian Institute of Technology, LKR Leichtmetallkompetenzzentrum Ranshofen GmbH, Lamprechtshausenerstraße 61, 5282 Ranshofen Braunau, Austria Abstract Within the framework of multi-functional and multi-material additive manufacturing, hollow structures made of AA6063 (AlMgSi0,5) were manufactured by wire arc additive manufacturing (WAAM). These form the basis for a motorcycle handlebar, which has to resist 3-dimensional bending fatigue load cases with respect to the mid axis of the handlebar: lifting the motorbike and braking. The latter one was chosen for an experimental and numerical fatigue assessment. For the experimental analysis, axial bending fatigue testing was chosen to derive Wöhler curves for the bending moment using the Maximum Likelihood Estimation. On the basis of 3d scans of the experimentally investigated WAAM hollow structures, finite element models were derived. From the load simulations of these models crack initiation locations were predicted and a fatigue assessment based on Von Mises equivalent stresses was carried out, resulting in a stress concentration factor of 2. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license ( https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons Keywords: WAAM; aluminum; defect; fatigue assessment; numerical analysis Third European Conference on the Structural Integrity of Additively Manufactures Materials (ESIAM23) Development and fatigue assessment of wire arc additively manufactured hollow structures made of AA6063 as a basis for functional integrated sections applied to a motorcycle handlebar Benjamin Möller a *, Marvin Kiel a , Rainer Wagener a , Enrico Taliani a , Richard Kordaß b , Michael Schramm b , Rudolf Gradinger c a Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany b EDAG Engineering GmbH, Kreuzberger Ring 40, 65205 Wiesbaden, Germany c AIT Austrian Institute of Technology, LKR Leichtmetallkompetenzzentrum Ranshofen GmbH, Lamprechtshausenerstraße 61, 5282 Ranshofen Braunau, Austria Third European Conference on the Structural Integrity of Additively Manufactures Materials (ESIAM23)

* Corresponding author. Tel.: +49-6151-705-8443 E-mail address: benjamin.moeller@lbf.fraunhofer.de * Corresponding author. Tel.: +49-6151-705-8443 E-mail address: benjamin.moeller@lbf.fraunhofer.de

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license ( https://creativecommons.org/licenses/by-nc-nd/4. 0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons 2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license ( https://creativecommons.org/licenses/by-nc-nd/4. 0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons 10.1016/j.prostr.2024.01.024