PSI - Issue 57

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2023) 000 – 000

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 57 (2024) 42–52

© 2024 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 Fatigue Design 2023 organizers Abstract Wire arc additive manufacturing (WAAM) is a metal 3D printing technique well recognised in the construction sector for its high efficiency, cost-effectiveness and flexibility in build scales. However, there remains a lack of fundamental data on the structural performance of WAAM elements, especially regarding their fatigue behaviour. A comprehensive experimental study into the fatigue behaviour of WAAM steel plates has therefore been undertaken and is reported herein. Following geometric and mechanical characterisation, a series of WAAM coupons was tested under uniaxial high-cycle fatigue loading. A total of 75 fatigue tests on both as-built and machined coupons, covering various stress ranges and stress ratios, have been conducted. The fatigue test results were analysed using constant life diagrams (CLDs) and S - N (stress-life) diagrams. The CLDs revealed that the fatigue strength of the as-built WAAM steel was relatively insensitive to the different stress ratios. The S - N diagrams showed that the surface undulations resulted in a reduction of about 35% in the fatigue endurance limit for the as-built WAAM material relative to the machined material, and a reduction of about 60% in fatigue life under the same load level. Preliminary S - N curves were also proposed for the WAAM steel. © 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 Fatigue Design 2023 organizers Keywords: Experiments; Fatigue life; Geometric variability; Metal 3D printing; Wire arc additive manufacturing. - - - Fatigue Design 2023 (FatDes 2023) Fatigue behaviour of wire arc additively manufactured sheet material Cheng Huang a,* , Lingzhen Li b,c , Niels Pichler b,c , Elyas Ghafoori b,c,d , Leroy Gardner a a Department of Civil and Environmental Engineering, Imperial College London, London SW7 2BX, UK b Empa, Swiss Federal Laboratories for Materials Science and Technology, Dübendorf 8600, Switzerland c Department of Civil, Environmental and Geomatic Engineering, ETH Zürich, Zürich 8092, Switzerland d Institute for Steel Construction, Faculty of Civil Engineering and Geodetic Science, Leibniz University Hannover, Hannover 30167, Germany a b c d

* Corresponding author. Tel.: +44-739-562-9353; fax: +44-739-562-9353. E-mail address: cheng.huang118@imperial.ac.uk

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 Fatigue Design 2023 organizers

2452-3216 © 2024 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 Fatigue Design 2023 organizers 10.1016/j.prostr.2024.03.006