PSI - Issue 66
Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2025) 000 – 000 Available online at www.sciencedirect.com ScienceDirect
www.elsevier.com/locate/procedia
ScienceDirect
Procedia Structural Integrity 66 (2024) 331–336
8th International Conference on Crack Paths Tribo-mechanical fracture analysis of additively manufactured Ti-6Al-4V under cyclic loading Grzegorz Glodek a , Sanjay Gothivarekar a , Brecht Van Hooreweder b , Reza Talemi a, *
Elooi Laboratory, Department of Materials Engineering, KU Leuven, 3001 Leuven, Belgium Department of Mechanical Engineering, KU Leuven, Celestijnenlaan 300b, B 3001 Leuven, Belgium
Abstract Fretting fatigue is a tribological process that causes damage at the interface of two contacting surfaces and significantly reduces the fatigue life of components. The dovetail joint connection between a turbine blade and disk is a critical example of such an industrial application. This study investigates the fretting fatigue behavior of additively manufactured (AM) Ti-6Al-4V components in a dovetail configuration. A dedicated test apparatus was developed to assess the performance of 3D-printed material in comparison to its wrought counterpart. Additionally, a finite element model was created to analyze stress distribution at the contact interface. The numerical simulations confirmed the presence of stress concentrations at the contact edges and highlighted high-stress fields at the curved edges. The experimental results indicate that the tribomechanical, fretting fatigue performance of AM-Ti64 is comparable to that of the wrought material, with both exhibiting similar lifetimes under the applied loading conditions. However, in the case of AM-Ti64, presence of internal defects caused early failures outside the contact zone. These critical defects were located near the surface in critical areas such as curved edges, which substantially reduced the fatigue lifetime of these components, even at lower load levels. © 2025 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 CP 2024 Organizers Keywords: Fretting Fatigue, Additive Manufacturing, Ti-6Al-4V, Internal Defects © 2025 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 CP 2024 Organizers
* Corresponding author. Tel.: +32-9-331-65-01; fax: +32-9-331-65-01. E-mail address: reza.talemi@kuleuven.be
2452-3216 © 2025 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 CP 2024 Organizers
2452-3216 © 2025 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 CP 2024 Organizers 10.1016/j.prostr.2024.11.083
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