PSI - Issue 68

Shahriar Afkhami et al. / Procedia Structural Integrity 68 (2025) 929–935 S. Afkhami et al. / Structural Integrity Procedia 00 (2025) 000–000

935

7

Conclusions This study investigated the influence of design optimization and material selection on the fatigue performance of a bicycle crank arm. The results showed that fatigue performance does not solely rely on the strength of the utilized metal; design details, defect content, and surface quality of the additively manufactured metal must also be included in the considerations. In this regard, local stress concentration factors, as a design-related parameter, and surface quality, as a manufacturing parameter, seem to have the most significant influence. Acknowledgments The authors would like to acknowledge the financial support of Business Finland for funding this research via the DREAMS project; also, Amexci is highly appreciated for manufacturing the components studied in this research. References [1] J. Plocher, A. Panesar, Review on design and structural optimisation in additive manufacturing: Towards next generation lightweight structures, Mater Des 183 (2019) 108164. https://doi.org/10.1016/j.matdes.2019.108164. [2] S.H. Huang, P. Liu, A. Mokasdar, L. Hou, Additive manufacturing and its societal impact: a literature review, The International Journal of Advanced Manufacturing Technology 67 (2013) 1191–1203. https://doi.org/10.1007/s00170-012-4558-5. [3] O. Ibhadode, Z. Zhang, J. Sixt, K.M. Nsiempba, J. Orakwe, A. Martinez-Marchese, O. Ero, S.I. Shahabad, A. Bonakdar, E. Toyserkani, Topology optimization for metal additive manufacturing: current trends, challenges, and future outlook, Virtual Phys Prototyp 18 (2023). https://doi.org/10.1080/17452759.2023.2181192. [4] N.A. Aziz, N.A.A. Adnan, D.A. Wahab, A.H. Azman, Component design optimisation based on artificial intelligence in support of additive manufacturing repair and restoration: Current status and future outlook for remanufacturing, J Clean Prod 296 (2021) 126401. https://doi.org/10.1016/j.jclepro.2021.126401. [5] A. Wiberg, J. Persson, J. Ölvander, Design for additive manufacturing – a review of available design methods and software, Rapid Prototyp J 25 (2019) 1080–1094. https://doi.org/10.1108/RPJ-10-2018-0262. [6] EOS GmbH, Metal Powder for 3D Printing | EOS | EOS GmbH, (2024). https://www.eos.info/en-us/metal solutions/metal-materials (accessed August 6, 2024). [7] S. Afkhami, M. Dabiri, H. Piili, T. Björk, Effects of manufacturing parameters and mechanical post-processing on stainless steel 316L processed by laser powder bed fusion, Materials Science and Engineering: A 802 (2021) 140660. https://doi.org/10.1016/j.msea.2020.140660. [8] Y. Geng, I. Panchenko, X. Chen, Y. Ivanov, S. Konovaloc, Wire arc additive manufacturing Al-5.0 Mg alloy: Microstructures and phase composition, Materials Characterization 187 (2022) 111875. https://doi.org/10.1016/j.matchar.2022.111875. [9] W. Xu, S. Sun, J. Elambasseril, Q. Liu, M. Brandt, M. Qian, Ti-6Al-4V Additively Manufactured by Selective Laser Melting with Superior Mechanical Properties, JOM 67 (2015) 668–673. https://doi.org/10.1007/s11837 015-1297-8. [10] E. Brandl, C. Leyens, F. Palm, Mechanical Properties of Additive Manufactured Ti-6Al-4V Using Wire and Powder Based Processes, IOP Conf Ser Mater Sci Eng 26 (2011) 012004. https://doi.org/10.1088/1757 899X/26/1/012004. [11] S. Afkhami, M. Dabiri, S.H. Alavi, T. Björk, A. Salminen, S. Habib Alavi, T. Björk, A. Salminen, Fatigue characteristics of steels manufactured by selective laser melting, Int J Fatigue 122 (2019) 72–83. https://doi.org/10.1016/j.ijfatigue.2018.12.029. [12] A.Y. Al-Maharma, S.P. Patil, B. Markert, Effects of porosity on the mechanical properties of additively manufactured components: a critical review, Mater Res Express 7 (2020) 122001. https://doi.org/10.1088/2053-1591/abcc5d.