PSI - Issue 34

ScienceDirect Structural Int grity Procedia 00 (2021) 000 – 000 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2021) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Procedia Structural Integrity 34 (2021) 160–165 Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia

www.elsevier.com/locate/procedia

© 2021 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 Esiam organisers From the structural stress assessment of a LBW aluminum component, a sufficiently low difference in the fatigue life between the FE-based estimation and the experiment is obtained. However, this result is an outcome of a specific modeling and meshing approach. Consideration of multiaxial load cases or a general validation is not part of this study. Keywords: additive manufacturing, dissimilar aluminum weld, lap joint, peel specimen, notch stress, structural stress, FAT class, battery carrier © 2021 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 Esiam organisers Abstract The fatigue assessment of dissimilar aluminum materials is made by notch stresses for laser beam welded joints between additively manufactured AlSi10Mg and conventionally manufactured EN AW-6082 T6. The assessment is extended from the joint types of single side welded lap joints and peel T-joints both with an I-shape seam weld to lap joints with fillet welds on both sides. The results of notch stresses based on the von Mises stress hypothesis for lap joints with fillet welds exceed FAT 142 and even FAT 160 recommended for weld toe failure, assuming a slope of the design S-N curve of k = 5 in case of thin and flexible structures. Notch stresses of both joint types with I-shape seam welds are in good agreement. Recommended notch stress fatigue classes of FAT 160 or higher cannot be applied in a safe fatigue assessment for these joint types, since some lower stress values (for peel T-joints) are found. The scatter of an overall notch stress S-N curve for LBW joints with I-shape and fillet welds is increased. From the structural stress assessment of a LBW aluminum component, a sufficiently low difference in the fatigue life between the FE-based estimation and the experiment is obtained. However, this result is an outcome of a specific modeling and meshing approach. Consideration of multiaxial load cases or a general validation is not part of this study. Keywords: additive manufacturing, dissimilar aluminum weld, lap joint, peel specimen, notch stress, structural stress, FAT class, battery carrier © 2021 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 Esiam organisers s r s r e s a s K P The second European Conference on the Structural Integrity of Additively Manufactured Materials Fatigue assessment of laser beam welds between AlSi10Mg AM-structures and conventionally manufactured aluminum by local approaches Benjamin Möller*, Kai Schnabel, Matilde Scurria, Andre Jöckel, Jörg Baumgartner Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstr. 47, 64289 Darmstadt, Germany Abstract The fatigue assessment of dissimilar aluminum materials is made by notch stresses for laser beam welded joints between additively manufactured AlSi10Mg and conventionally manufactured EN AW-6082 T6. The assessment is extended from the joint types of single side welded lap joints and peel T-joints both with an I-shape seam weld to lap joints with fillet welds on both sides. The results of notch stresses based on the von Mises stress hypothesis for lap joints with fillet welds exceed FAT 142 and even FAT 160 recommended for weld toe failure, assuming a slope of the design S-N curve of k = 5 in case of thin and flexible structures. Notch stresses of both joint types with I-shape seam welds are in good agreement. Recommended notch stress fatigue classes of FAT 160 or higher cannot be applied in a safe fatigue assessment for these joint types, since some lower stress values (for peel T-joints) are found. The scatter of an overall notch stress S-N curve for LBW joints with I-shape and fillet welds is increased. The second European Conference on the Structural Integrity of Additively Manufactured Materials Fatigue assessment of laser beam welds between AlSi10Mg AM-structures and conventionally manufactured luminum by local approaches Benjamin Möller*, Kai Schnabel, Matilde Scurria, Andre Jöckel, Jörg Baumgartner Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstr. 47, 64289 Darmstadt, Germany T

* Corresponding author. Tel.: +49 6151 705 8443; fax: +49 6151 705 214. E-mail address: benjamin.moeller@lbf.fraunhofer.de

2452-3216 © 2021 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 Esiam organisers 10.1016/j.prostr.2021.12.023 2452-3216 © 2021 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 Esiam organisers 2452-3216 © 2021 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 Esiam organisers * Corresponding author. Tel.: +49 6151 705 8443; fax: +49 6151 705 214. E-mail address: benjamin.moeller@lbf.fraunhofer.de P e