PSI - Issue 53

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2022) 000–000 ScienceDirect Structural Integrity Procedia 00 (2022) 000–000

www.elsevier.com/locate/procedia

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 53 (2024) 161–171

© 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 © 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: Fatigue Life Curve, Representative Structural Elements, Roughness, Wire Arc Additive Maufacturing, Cyclic material behavior Abstract The relevance of the additive manufacturing technology is steadily growing, especially for metallic structures. In order to exploit the lightweight design potential for cyclically loaded safety parts in industrial applications, tools and methods are required to describe the cyclic material behavior in order to simulate the structural behavior with respect to the build conditions. Furthermore, a fatigue approach has to ensure the transfer of the cyclic behavior derived by the use of specimens to arbitrary structures and loading conditions. In order to enable a high-quality design process, Representative Structural Elements will be used to describe the cyclic stress-strain behavior as well as the fatigue life from the Low Cycle Fatigue up to the Very High Cycle Fatigue. Therefore, the Fatigue Life Curve will be implemented to consider the load-time histories at different maximum stress amplitudes. For the transfer of the cyclic properties, determined on the basis of specimens, to arbitrary component geometries and loading scenarios, the importance of the description of the investigated material state is increased. It is also important to ensure that the characteristic values used also describe the intended properties or influences. Therefore, a new method for describing the surface structure is presented, which is based on the idea to consider the notch effect and stress concentrations as influencing variables on the fatigue strength. For this purpose, the surface profile is conceived as a sequence of geometrical notches and the notch sharpness is estimated using the ratio of local profile height and length between the respective peaks and valleys. It should be noted that the aim of this method of describing the surface condition is not to be able to derive a direct influencing factor, but rather to optimize and narrow down the range of validity of the Representative Structural Elements. © 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: Fatigue Life Curve, Representative Structural Elements, Roughness, Wire Arc Additive Maufacturing, Cyclic material behavior 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 Third European Conference on the Structural Integrity of Additively Manufactures Materials (ESIAM23) Deriving Representative Structural Elements for the fatigue approach of Wire Arc Additively Manufactured components Rainer Wagener*, Marvin Kiel Fraunhofer Insititute for Structural Durability and System Reliability LBF, Bartningstr. 47, 64289 Darmstadt, Germany Abstract The relevance of the additive manufacturing technology is steadily growing, especially for metallic structures. In order to exploit the lightweight design potential for cyclically loaded safety parts in industrial applications, tools and methods are required to describe the cyclic material behavior in order to simulate the structural behavior with respect to the build conditions. Furthermore, a fatigue approach has to ensure the transfer of the cyclic behavior derived by the use of specimens to arbitrary structures and loading conditions. In order to enable a high-quality design process, Representative Structural Elements will be used to describe the cyclic stress-strain behavior as well as the fatigue life from the Low Cycle Fatigue up to the Very High Cycle Fatigue. Therefore, the Fatigue Life Curve will be implemented to consider the load-time histories at different maximum stress amplitudes. For the transfer of the cyclic properties, determined on the basis of specimens, to arbitrary component geometries and loading scenarios, the importance of the description of the investigated material state is increased. It is also important to ensure that the characteristic values used also describe the intended properties or influences. Therefore, a new method for describing the surface structure is presented, which is based on the idea to consider the notch effect and stress concentrations as influencing variables on the fatigue strength. For this purpose, the surface profile is conceived as a sequence of geometrical notches and the notch sharpness is estimated using the ratio of local profile height and length between the respective peaks and valleys. It should be noted that the aim of this method of describing the surface condition is not to be able to derive a direct influencing factor, but rather to optimize and narrow down the range of validity of the Representative Structural Elements. Third European Conference on the Structural Integrity of Additively Manufactures Materials (ESIAM23) Deriving Representative Structural Elements for the fatigue approach of Wire Arc Additively Manufactured components Rainer Wagener*, Marvin Kiel Fraunhofer Insititute for Structural Durability and System Reliability LBF, Bartningstr. 47, 64289 Darmstadt, Germany

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.2024.01.020