PSI - Issue 53

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Benjamin Möller et al. / Procedia Structural Integrity 53 (2024) 190–202 Author name / Structural Integrity Procedia 00 (2023) 000–000

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4.2. Outlook The present investigation gives an insight on the fatigue assessment based on existing (known) WAAM structures. In the case of a fatigue estimation prior to the manufacturing process in the design phase, the starting point will be the ideal flat shape of the CAD model. Starting from this, assumptions based on general or specific knowledge on the real shape related to internal imperfections and surface conditions need to be taken into account. For the transfer to AM components, results concerning the fatigue notch effect from this investigation are valuable. However, the stress concentration of factor 2 between FE simulation results of “real” scanned and ideal flat model has to be connected to geometric measures of the fatigue relevant notches. Relevant parameters might be the notch radius or the notch opening angle, which will be from the “real” scanned models. Furthermore, Wagener and Kiel (2023) proposed to use the distribution of the peak-to-valley height to length ratio K R for a characterization of the surface profile and as a basis information for the stress concentration. The idea of Representative Structural Elements (RSE), also introduced for WAAM structures in Wagener and Kiel (2023), has the capability of deriving cyclic structural properties on specimen level with respect to irregularities such as pores, lack of fusions of surface profiles or surface roughness. Therefore, strain-controlled fatigue testing on as built small-scale flat specimens manufactured from WAAM wall structures will give deeper inside of effects of defects compared with polished specimens extracted in the same orientation from the walls. From a general perspective, the research of this investigation needs to be transferred to other materials processed by WAAM and to other AM process variants to gain further knowledge on the cyclic behavior of additively manufactured structures. Acknowledgements The authors would like to thank all project partners of the project Multi-Fun and beyond it making it possible to perform the work necessary for the investigations related to this publication. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 862617 – MULTI FUN References Gradinger, R., 2020. Novel methods of producing 3D hollows in parts produced by ded technologies. Metal Additive Manufacturing. Gradinger, R., Schnall, M., 2020. Neuartige Konzepte der Hohlkanalherstellung in wire+arc additiv gefertigten Werkzeugen. Additive Tooling 2020 - Symbiose von Additiver Fertigung und Werkzeugbau. Gradinger, R., Ucsnik, S.A., Karanovic, S., Klug, A., 2020. Multi-material 3D printing for components in electronic based system. AVL Research Networking Day 2020. Gradinger, R., 2023. Progress in multi-material design. Metal Additive Manufacturing Conference – Industrial Perspectives in Additive Technologies, 17-19 October 2023, WKO Vienna. Hohm, D., Gradinger, R.,2022. Integration of electrical conductors into light metall. 12. Ranshofener Leichtmetalltage 2022. MULTI-FUN project, 2023. Enabling Multi-Functional Performance through Multi-Material Additive Manufacturing. www.multi-fun.eu, webpage. Sonsino C.M., 2007. Course of SN-curves especially in the high-cycle fatigue regime with regard to component design and safety. Int J Fatigue 2007;29(12):2246–58. Spindel, J.E., Haibach, E., 1978. The Method of Maximum Likelihood applied to the Statistical Analysis of Fatigue Data including Run-Outs . S. E. E. International Conference , 3-6 April 1978, Coventry, pp. 7.1-7.23. Störzel, K., Baumgartner, J., 2021. Statistical evaluation of fatigue tests using maximum likelihood, Materials Testing 63 (2021) 8, 714–720. Taliani, E. 2023. Fatigue assessment of aluminum structures produced by Wire Arc Additive Manufacturing (WAAM), Masters Thesis, University of Pisa. (in preparation) Wagener, R.; Kiel, M., 2023. Deriving Representative Structural Elements for the fatigue approach of Wire Arc Additively Manufactured components, Structural Integrity Procedia

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